Subsurface deformation of the cutting process has attracted a great deal of attention due to its tight relationship with subsurface hardening, microstructure alteration, grain refinement, and white layer formation. To predict the subsurface deformation of the machined components, an analytical model is proposed in this paper. The mechanical and thermal loads exerted on the workpiece by the primary and tertiary shear zones are predicted by a combination of Oxley's predictive model and Fang's slip line field. The stress field and temperature field are calculated based on contact mechanics and the moving heat source theory, respectively. However, the elastic–plastic regime induced by the material yielding hinders the direct derivation of subsurface plastic deformation from the stress field and the work material constitutive model. To tackle this problem, a blending function of the increment of elastic strain is developed to derive the plastic strain. In addition, a sophisticated material constitutive model considering strain hardening, strain rate sensitivity, and thermal softening effects of work material is incorporated into this analytical model. To validate this model, finite element simulations of the subsurface deformation during orthogonal cutting of AISI 52100 steel are conducted. Experimental verification of the subsurface deformation is carried out through a novel subsurface deformation measurement technique based on digital image correlation (DIC) technique. To demonstrate applications of the subsurface deformation prediction, the subsurface microhardness of the machined component is experimentally tested and compared against the predicted values based on the proposed method.
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September 2017
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Subsurface Deformation Generated by Orthogonal Cutting: Analytical Modeling and Experimental Verification
Dong Zhang,
Dong Zhang
State Key Laboratory of Digital Manufacturing
Equipment and Technology,
Huazhong University of Science and Technology,
Wuhan 430074, China
Equipment and Technology,
Huazhong University of Science and Technology,
Wuhan 430074, China
Search for other works by this author on:
Xiao-Ming Zhang,
Xiao-Ming Zhang
State Key Laboratory of Digital Manufacturing
Equipment and Technology,
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: zhangxm.duyi@gmail.com
Equipment and Technology,
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: zhangxm.duyi@gmail.com
Search for other works by this author on:
Jürgen Leopold,
Jürgen Leopold
Precision Engineering Department,
Fraunhofer Institute for Machine Tools and
Forming Technology,
Chemnitz 09661, Germany
Fraunhofer Institute for Machine Tools and
Forming Technology,
Chemnitz 09661, Germany
Search for other works by this author on:
Han Ding
Han Ding
State Key Laboratory of Digital Manufacturing
Equipment and Technology,
Huazhong University of Science and Technology,
Wuhan 430074, China
Equipment and Technology,
Huazhong University of Science and Technology,
Wuhan 430074, China
Search for other works by this author on:
Dong Zhang
State Key Laboratory of Digital Manufacturing
Equipment and Technology,
Huazhong University of Science and Technology,
Wuhan 430074, China
Equipment and Technology,
Huazhong University of Science and Technology,
Wuhan 430074, China
Xiao-Ming Zhang
State Key Laboratory of Digital Manufacturing
Equipment and Technology,
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: zhangxm.duyi@gmail.com
Equipment and Technology,
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: zhangxm.duyi@gmail.com
Jürgen Leopold
Precision Engineering Department,
Fraunhofer Institute for Machine Tools and
Forming Technology,
Chemnitz 09661, Germany
Fraunhofer Institute for Machine Tools and
Forming Technology,
Chemnitz 09661, Germany
Han Ding
State Key Laboratory of Digital Manufacturing
Equipment and Technology,
Huazhong University of Science and Technology,
Wuhan 430074, China
Equipment and Technology,
Huazhong University of Science and Technology,
Wuhan 430074, China
1Corresponding author.
Manuscript received January 19, 2017; final manuscript received May 31, 2017; published online July 18, 2017. Assoc. Editor: Radu Pavel.
J. Manuf. Sci. Eng. Sep 2017, 139(9): 094502 (12 pages)
Published Online: July 18, 2017
Article history
Received:
January 19, 2017
Revised:
May 31, 2017
Citation
Zhang, D., Zhang, X., Leopold, J., and Ding, H. (July 18, 2017). "Subsurface Deformation Generated by Orthogonal Cutting: Analytical Modeling and Experimental Verification." ASME. J. Manuf. Sci. Eng. September 2017; 139(9): 094502. https://doi.org/10.1115/1.4036994
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