0000000000210562
AUTHOR
José Outeiro
Multi-physical analysis of the electrochemical behaviour of OFHC copper surfaces obtained by orthogonal cutting
International audience; As mechanical, physical, and microstructural properties of metals can be significantly affected by the machining process, electrochemical properties and corrosion resistance are consequently altered. Manufacturers should control the impact of cutting conditions on surface integrity, as it will affect the component’s functional performance and life. This study addresses the case of orthogonal cutting of oxygen-free high conductivity (OFHC) copper. A set of experiments was performed and a statistical analysis was conducted to reveal the relationship between the cutting conditions and the surface integrity in terms of residualstresses, microstructure, plastic deformatio…
Friction Model for Tool/Work Material Contact Applied to Surface Integrity Prediction in Orthogonal Cutting Simulation
Abstract Tribological behavior at both tool/chip and tool/work material interfaces should be highly considered while simulating the machining process. In fact, it is no longer accurate to suppose one independent constant friction coefficient at the tool/chip interface, since in reality it depends on the applied contact conditions, including the sliding velocity and pressure. The contact conditions at both above mentioned interfaces may affect the thermal and mechanical phenomena and consequently the surface integrity predictions. In this article, the influence of contact conditions (sliding velocity) on the tribological behavior of uncoated tungsten carbide tool against OFHC copper work mat…
A physical-based constitutive model for surface integrity prediction in machining of OFHC copper
International audience; Due to the rising interest in predicting machined surface integrity and sustainability, various models for metal cutting simulation have been developed. However, their accuracy depends deeply on the physical description of the machining process. This study aims to develop an orthogonal cutting model for surface integrity prediction, which includes a physical-based constitutive model of Oxygen Free High Conductivity (OFHC) copper. This constitutive model incorporates the effects of the state of stress and microstructure on the work material behavior, as well as a dislocation density-based model for surface integrity prediction. The coefficients of the constitutive mod…
Influence of cutting process mechanics on surface integrity and electrochemical behavior of OFHC copper
The authors gratefully acknowledge the support received from IC ARTS and CEA Valduc; International audience; Superfinishing machining has a particular impact on cutting mechanics, surface integrity and local electrochemical behavior. In fact, material removal during this process induces geometrical, mechanical and micro-structural modifications in the machined surface and sub-surface. However, a conventional 3D cutting process is still complex to study in terms of analytical/numerical modeling and experimental process monitoring. So, researchers are wondering if a less intricate configuration such as orthogonal cutting would be able to provide information about surface integrity as close as…
An Experimental Investigation of Residual Stresses in Hard Machining of AISI 52100 Steel
In this paper an experimental investigation was conducted to determine the effects of the tool cutting-edge geometry, workpiece hardness, cutting speed, and microstructural changes (white and dark layers) on the residual stresses in dry orthogonal hard machining of AISI 52100 steel. X-ray diffraction technique was used to obtain in-depth residual stresses profiles in both axial and circumferential directions. The results show that tool geometry, workpiece hardness and cutting parameters significantly affect the surface residual stress, maximum compressive residual stress below the machined surface and its location. Moreover, microstructural analysis shows that thermally-induced phase transf…
On the optimization of the cutting conditions for an improved corrosion resistance of OFHC copper
International audience; Machining has a particular impact on the surface integrity and on corrosion resistance of components. In fact, material removal induces geometrical, mechanical and micro-structural modifications in the machined surface and sub-surface that alter the electrochemical behavior of the material, and so the aging process. In this study, oxygen free high conductivity copper (OFHC) has machined under orthogonal cutting conditions using uncoated cemented carbide tools. Then, the corrosion resistance in 0.1 M NaCl salt fog atmosphere of the machined samples is analyzed. Finally, the optimal cutting conditions, including the tool geometry, for an improved corrosion resistance a…
Experimental and numerical assessment of subsurface plastic deformation induced by OFHC copper machining
Strain distributions in the machined surface and subsurface of OFHC copper workpieces were determined experimentally and through numerical simulations. An experimental setup, comprising a double frame camera and a pulsed laser, was developed to measure the displacement fields using the digital image correlation (DIC) technique; strain distributions were then calculated. A numerical orthogonal cutting model was also developed and applied in order to predict such distributions. Comparison between simulated and measured results enabled an understanding of the fundamental mechanisms of plastic deformation of the machined surface of OFHC copper.; International audience; Strain distributions in t…
Orthogonal cutting simulation of OFHC copper using a new constitutive model considering the state of stress and the microstructure effects
International audience; This work aims to develop an orthogonal cutting model for surface integrity prediction, which incorporates a new constitutive model of Oxygen Free High Conductivity (OFHC) copper. It accounts for the effects of the state of stress on the flow stress evolution up to fracture. Moreover, since surface integrity parameters are sensitive to the microstructure of the work material, this constitutive model highlights also the recrystallization effects on the flow stress. Orthogonal cutting model is validated using experimental designed cutting tests. More accurate predictions were obtained using this new constitutive model comparing to the classical Johnson-Cook model.