This work investigates the effects of turning process parameters on recrystallization behavior in Al alloy 7075. To realize this purpose, samples were machined under different cutting speeds and material feed rates at two extreme levels. Microscopy imaging reveals that activation of dynamic recrystallization or grain growth depends on the combination of applied cutting parameters. Increasing the cutting speed intensifies recrystallization, while the feed rate governs the grain growth. Adjusting the cutting parameters enables one to obtain a desired average grain size below the machined surface, up to a ∼180 μm depth. The average grain size of the initial material was 31.6 μm. The imposed processing parameters successfully yielded average grain sizes in the range from 19 to 44 μm. Additionally, a computational framework work consisting of finite-element analysis (FEA) coupled with kinetic-based modeling of recrystallization was developed, which is capable of following the trend of change in the average grain size and acceptably predicts the evolved average grain size.
Issue Section:
Research Papers
Topics:
Aluminum alloys,
Cutting,
Grain size,
Machining,
Modeling,
Recrystallization,
Temperature,
Simulation,
Turning
References
References
1.
Altintas
, Y.
2012
, Manufacturing Automation: Metal Cutting Mechanics, Machine Tool Vibrations, and CNC Design
, Cambridge University Press
, New York.2.
Lin
, J.
Balint
, D.
Pietrzyk
, M.
2012
, Microstructure Evolution in Metal Forming Processes
, Elsevier
, Oxford, UK.3.
Bontcheva
, N.
Petzov
, G.
2003
, “Microstructure Evolution During Metal Forming Processes
,” Comput. Mater. Sci.
, 28
(3
), pp. 563
–573
.4.
Tabei
, A.
Li
, D.
Lavender
, C.
Garmestani
, H.
2015
, “Investigation of Precipitate Refinement in Mg Alloys by an Analytical Composite Failure Model
,” Mech. Mater.
, 89
, pp. 59
–71
.5.
Tabei
, S.
Sheidaei
, A.
Baniassadi
, M.
Pourboghrat
, F.
Garmestani
, H.
2013
, “Microstructure Reconstruction and Homogenization of Porous Ni-YSZ Composites for Temperature Dependent Properties
,” J. Power Sources
, 235
(1
), pp. 74
–80
.6.
Tabei
, A.
Li
, D. S.
Lavender
, C. A.
Garmestani
, H.
2014
, “Effects of Morphology and Geometry of Inclusions on Two-Point Correlation Statistics in Two Phase Composites
,” Int. J. Theor. Appl. Multiscale Mech.
, 3
(1
), pp. 1
–17
.7.
Tabei
, A.
Fergani
, O.
Garmestani
, H.
Liang
, S. Y.
2014
, “Analysis of Micro-Texture and Grain Size Distributions in Machined Aluminum Alloy 7075
,” Adv. Mater. Res.
, 1052
(1
), pp. 489
–494
.8.
Basu
, S.
Shankar
, M. R.
2015
, “Crystallographic Textures Resulting From Severe Shear Deformation in Machining
,” Metall. Mater. Trans. A
, 46
(2
), pp. 801
–812
.9.
Arısoy
, Y. M.
Özel
, T.
2014
, “Prediction of Machining Induced Microstructure in Ti-6Al-4V Alloy Using 3-D FE-Based Simulations: Effects of Tool Micro-Geometry, Coating and Cutting Conditions
,” J. Mater. Process. Technol.
, 220
, pp. 1
–16
.10.
Rotella
, G.
Dillon
, O. W.
, Jr.Umbrello
, D.
Settineri
, L.
Jawahir
, I. S.
2013
, “Finite Element Modeling of Microstructural Changes in Turning of AA7075-T651 Alloy
,” J. Manuf. Processes
, 15
(1
), pp. 87
–95
.11.
Swaminathan
, S.
Shankar
, M. R.
Lee
, S.
Hwang
, J.
King
, A. H.
Kezar
, R. F.
Rao
, B. C.
Brown
, T. L.
Chandrasekar
, S.
Compton
, W. D.
2005
, “Large Strain Deformation and Ultra-Fine Grained Materials by Machining
,” Mater. Sci. Eng. A
, 410
, pp. 358
–363
.12.
Bissey-Breton
, S.
Gravier
, J.
Vignal
, V.
2011
, “Impact of Superfinish Turning on Surface Integrity of Pure Copper
,” Proc. Eng.
, 19
, pp. 28
–33
.13.
Rollett
, A.
Humphreys
, F.
Rohrer
, G. S.
Hatherly
, M.
2004
, Recrystallization and Related Annealing Phenomena
, Elsevier
, Oxford, UK.14.
Shankar
, M. R.
Chandrasekar
, S.
King
, A. H.
Compton
, W. D.
2005
, “Microstructure and Stability of Nanocrystalline Aluminum 6061 Created by Large Strain Machining
,” Acta Mater.
, 53
(18
), pp. 4781
–4793
.15.
Courbon
, C.
Mabrouki
, T.
Rech
, J.
Mazuyer
, D.
Perrard
, F.
D'Eramo
, E.
2013
, “Towards a Physical FE Modelling of a Dry Cutting Operation: Influence of Dynamic Recrystallization When Machining AISI 1045
,” Proc. CIRP
, 8
, pp. 515
–520
.16.
M'Saoubi
, R.
Larsson
, T.
Outeiro
, J.
Guo
, Y.
Suslov
, S.
Saldana
, C.
Chandrasekar
, S.
2012
, “Surface Integrity Analysis of Machined Inconel 718 Over Multiple Length Scales
,” CIRP Ann. Manuf. Technol.
, 61
(1
), pp. 99
–102
.17.
Ghosh
, S.
Kain
, V.
2010
, “Microstructural Changes in AISI 304L Stainless Steel Due to Surface Machining: Effect on Its Susceptibility to Chloride Stress Corrosion Cracking
,” J. Nucl. Mater.
, 403
(1
), pp. 62
–67
.18.
Ni
, H.
Elmadagli
, M.
Alpas
, A.
2004
, “Mechanical Properties and Microstructures of 1100 Aluminum Subjected to Dry Machining
,” Mater. Sci. Eng. A
, 385
(1
), pp. 267
–278
.19.
Ding
, H.
Shin
, Y. C.
2011
, “Dislocation Density-Based Grain Refinement Modeling of Orthogonal Cutting of Commercially Pure Titanium
,” ASME
Paper No. MSEC2011-50220.20.
Ding
, H.
Shen
, N.
Shin
, Y. C.
2011
, “Modeling of Grain Refinement in Aluminum and Copper Subjected to Cutting
,” Comput. Mater. Sci.
, 50
(10
), pp. 3016
–3025
.21.
Rotella
, G.
Umbrello
, D.
2014
, “Numerical Simulation of Surface Modification in Dry and Cryogenic Machining of AA7075 Alloy
,” Proc. CIRP
, 13
, pp. 327
–332
.22.
Jafarian
, F.
Ciaran
, M. I.
Umbrello
, D.
Arrazola
, P.
Filice
, L.
Amirabadi
, H.
2014
, “Finite Element Simulation of Machining Inconel 718 Alloy Including Microstructure Changes
,” Int. J. Mech. Sci.
, 88
, pp. 110
–121
.23.
Totten
, G. E.
MacKenzie
, D. S.
2003
, Handbook of Aluminum: Vol. 1: Physical Metallurgy and Processes
, Vol. 1
, CRC Press
, Boca Raton, FL.24.
Le
, K.
Kochmann
, D.
2009
, “A Simple Model for Dynamic Recrystallization During Severe Plastic Deformation
,” Arch. Appl. Mech.
, 79
(6–7
), pp. 579
–586
.25.
Bacca
, M.
Hayhurst
, D. R.
McMeeking
, R. M.
2015
, “Continuous Dynamic Recrystallization During Severe Plastic Deformation
,” Mech. Mater.
, 90
, pp. 148
–156
.26.
Liu
, R.
Salahshoor
, M.
Melkote
, S.
Marusich
, T.
2015
, “A Unified Material Model Including Dislocation Drag and Its Application to Simulation of Orthogonal Cutting of OFHC Copper
,” J. Mater. Process. Technol.
, 216
, pp. 328
–338
.27.
Brar
, N.
Joshi
, V.
Harris
, B.
2009
, “Constitutive Model Constants for Al7075-T651 and Al7075-T6
,” AIP Conf. Proc.
, 1195
, p. 945.28.
Kolmogorov
, A. N.
1937
, “On the Statistical Theory of the Crystallization of Metals
,” Bull. Acad. Sci. USSR, Math. Ser.
, 1
, pp. 355
–359
.29.
Johnson
, W. A.
Mehl
, R. F.
1939
, “Reaction Kinetics in Processes of Nucleation and Growth
,” Trans. Metall. Soc. AIME
, 135
(8
), pp. 396
–415
.30.
Avrami
, M.
1939
, “Kinetics of Phase Change—I: General Theory
,” J. Chem. Phys.
, 7
(12
), pp. 1103
–1112
.31.
Quan
, G.-Z.
Mao
, Y.-P.
Li
, G.-S.
Lv
, W.-Q.
Wang
, Y.
Zhou
, J.
2012
, “A Characterization for the Dynamic Recrystallization Kinetics of As-Extruded 7075 Aluminum Alloy Based on True Stress–Strain Curves
,” Comput. Mater. Sci.
, 55
, pp. 65
–72
.32.
Jonas
, J. J.
Quelennec
, X.
Jiang
, L.
Martin
, É.
2009
, “The Avrami Kinetics of Dynamic Recrystallization
,” Acta Mater.
, 57
(9
), pp. 2748
–2756
.33.
Roberts
, W.
Boden
, H.
Ahlblom
, B.
1979
, “Dynamic Recrystallization Kinetics
,” Metal Sci.
, 13
(3–4
), pp. 195
–205
.34.
Deschamps
, A.
Brechet
, Y.
1998
, “Influence of Predeformation and Ageing of an Al–Zn–Mg Alloy—II: Modeling of Precipitation Kinetics and Yield Stress
,” Acta Mater.
, 47
(1
), pp. 293
–305
.35.
Hines
, J.
Vecchio
, K.
1997
, “Recrystallization Kinetics Within Adiabatic Shear Bands
,” Acta Mater.
, 45
(2
), pp. 635
–649
.36.
Medina
, S. F.
Hernandez
, C. A.
1996
, “Modelling of the Dynamic Recrystallization of Austenite in Low Alloy and Microalloyed Steels
,” Acta Mater.
, 44
(1
), pp. 165
–171
.37.
Souza
, R.
Silva
, E.
Jorge
, A.
, Jr.Cabrera
, J.
Balancin
, O.
2013
, “Dynamic Recovery and Dynamic Recrystallization Competition on a Nb- and N-Bearing Austenitic Stainless Steel Biomaterial: Influence of Strain Rate and Temperature
,” Mater. Sci. Eng. A
, 582
, pp. 96
–107
.38.
Kugler
, G.
Turk
, R.
2004
, “Modeling the Dynamic Recrystallization Under Multi-Stage Hot Deformation
,” Acta Mater.
, 52
(15
), pp. 4659
–4668
.39.
Yeom
, J. T.
Lee
, C. S.
Kim
, J. H.
Park
, N.-K.
2007
, “Finite-Element Analysis of Microstructure Evolution in the Cogging of an Alloy 718 Ingot
,” Mater. Sci. Eng. A
, 449
, pp. 722
–726
.40.
Yang
, X.
Miura
, H.
Sakai
, T.
2002
, “Continuous Dynamic Recrystallization in a Superplastic 7075 Aluminum Alloy
,” Mater. Trans.
, 43
(10
), pp. 2400
–2407
.41.
Gholinia
, A.
Humphreys
, F.
Prangnell
, P.
2002
, “Production of Ultra-Fine Grain Microstructures in Al–Mg Alloys by Coventional Rolling
,” Acta Mater.
, 50
(18
), pp. 4461
–4476
.42.
Bolouri
, A.
Shahmiri
, M.
Kang
, C. G.
2012
, “Coarsening of Equiaxed Microstructure in the Semisolid State of Aluminum 7075 Alloy Through SIMA Processing
,” J. Mater. Sci.
, 47
(8
), pp. 3544
–3553
.43.
Asgharzadeh
, H.
McQueen
, H.
2015
, “Grain Growth and Stabilisation of Nanostructured Aluminium at High Temperatures: Review
,” Mater. Sci. Technol.
31
(9
), 1016
–1034
.44.
Sakai
, T.
Miura
, H.
Goloborodko
, A.
Sitdikov
, O.
2009
, “Continuous Dynamic Recrystallization During the Transient Severe Deformation of Aluminum Alloy 7475
,” Acta Mater.
, 57
(1
), pp. 153
–162
.Copyright © 2016 by ASME
You do not currently have access to this content.
