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Experimental and finite element analysis of machinability of AL-6XN super austenitic stainless steel

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Abstract

This paper presents a finite element cutting model based on physical microstructure to investigate the thermo-mechanical behaviour of AL-6XN Super Austenitic Stainless Steel in the primary shear zone. Frozen chip root samples were created under dry turning operation to observe the plasticity behaviour occurring in the shear zones to compare with the model for analysis. Chip samples were generated under cutting velocities at 65 and 94 m/min, feed rate at 0.2 mm/rev and depth of cut at 1 mm. Temperature on the cutting zone was recorded by infrared thermal camera. Secondary and backscatter electron detectors were used to investigate the deformed microstructure and to calculate the plastic strain. Experimental results showed the formation of microcracks (build-up edge triggers) at the chip root stagnation zone of both samples. The austenite phase patterns were evident against the cutting tool tip in the stagnation zone of the chip root fabricated at 65 m/min. The movement of these patterns caused the formation of the slip lines within the grains. The backscatter diffraction maps showed the formation of special grain boundaries within the slip lines, work-hardening layer and in the chip region. Strain measurements in the microstructures of the chip roots fabricated at 94 and 65 m/min showed high values of 6.5 and 5.7 (mm/mm) respectively. The finite element model was used to measure the stress, strain, temperature and chip morphology. Numerical results were compared to the outcomes of the experimental work to validate the finite element model. The model validating process showed good agreement between the experimental and numerical results, and the error values were calculated. For a 94- and 65-m/min cutting speeds, 7.5 and 5.2% were the errors in the strain, 3 and 2.5% were the error in the temperature and 4.7 and 6.8% were the error in the shear plane angles.

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Authors and Affiliations

  1. School of Engineering, Deakin University, 75 Pigdon rd, Waurn Ponds, VIC, 3216, Australia

    Mohanad Alabdullah, Ashwin Polishetty, Junior Nomani & Guy Littelfair

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  1. Mohanad Alabdullah
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  2. Ashwin Polishetty
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  3. Junior Nomani
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  4. Guy Littelfair
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Correspondence to Mohanad Alabdullah.

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Alabdullah, M., Polishetty, A., Nomani, J. et al. Experimental and finite element analysis of machinability of AL-6XN super austenitic stainless steel. Int J Adv Manuf Technol 91, 501–516 (2017). https://doi.org/10.1007/s00170-016-9766-y

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  • DOI: https://doi.org/10.1007/s00170-016-9766-y

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