Enhanced Surface Integrity from Cryogenic Machining of AZ31B Mg Alloy: A Physics-Based Analysis with Microstructure Prediction

Ninggang Shen; Hongtao Ding; Zhengwen Pu; I. S. Jawahir; Tao Jia

doi:10.1115/1.4034279

Enhanced Surface Integrity from Cryogenic Machining of AZ31B Mg Alloy: A Physics-Based Analysis with Microstructure Prediction

Ninggang Shen, Hongtao Ding, Zhengwen Pu, I. S. Jawahir, Tao Jia

Research output: Contribution to journal › Article › peer-review

41 Scopus citations

Abstract

The use of magnesium (Mg) alloy has been continuously on the rise with numerous expanded application in transportation/aerospace industries due to their lightweight and other areas, such as biodegradable medical implants. It was shown recently that machining can be used to improve the functional performance of Mg-based products/components, such as corrosion resistance, through engineered surface integrity. In this paper, the behavior of AZ31B Mg alloy in cryogenic machining was discussed firstly. The surface integrity can be significantly improved by introducing the ultrafine grained (UFG) layer due to the severe plastic deformation (SPD) effect during cryogenic machining. The mechanisms of microstructure evolution and plastic deformation were analyzed based on the experimental findings in literature. A physics-based constitutive model involving material plasticity and grain refinement is developed based on both slip and twinning mechanisms and successfully implemented in a finite-element (FE) analysis with multiple cutting passes to predict the microstructure evolution by nanocrystalline grain refinement and other improvement of the surface integrity in the cryogenic machining of AZ31B Mg alloy. With a more quantitative assessment, the FE model results are further discussed for grain refinement, changes in microhardness, residual stresses, and slip/twinning mechanism with the apparent SPD taking place due to rapid cryogenic cooling.

Original language	English
Article number	061012
Journal	Journal of Manufacturing Science and Engineering, Transactions of the ASME
Volume	139
Issue number	6
DOIs	https://doi.org/10.1115/1.4034279
State	Published - Jun 1 2017

Bibliographical note

Funding Information:
The authors gratefully acknowledge the financial support provided for the part of the study carried out at the University of Iowa by the National Science Foundation under Grant No. EPS-1101284 and State Key Laboratory of Mechanical System and Vibration, Shanghai Jiao Tong University, China under Grant No. MSV201514.

Publisher Copyright:
Copyright © 2017 by ASME.

Keywords

cryogenic machining
dislocation density
magnesium alloy
microstructure
surface integrity
twinning

ASJC Scopus subject areas

Control and Systems Engineering
Mechanical Engineering
Computer Science Applications
Industrial and Manufacturing Engineering

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10.1115/1.4034279

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title = "Enhanced Surface Integrity from Cryogenic Machining of AZ31B Mg Alloy: A Physics-Based Analysis with Microstructure Prediction",

abstract = "The use of magnesium (Mg) alloy has been continuously on the rise with numerous expanded application in transportation/aerospace industries due to their lightweight and other areas, such as biodegradable medical implants. It was shown recently that machining can be used to improve the functional performance of Mg-based products/components, such as corrosion resistance, through engineered surface integrity. In this paper, the behavior of AZ31B Mg alloy in cryogenic machining was discussed firstly. The surface integrity can be significantly improved by introducing the ultrafine grained (UFG) layer due to the severe plastic deformation (SPD) effect during cryogenic machining. The mechanisms of microstructure evolution and plastic deformation were analyzed based on the experimental findings in literature. A physics-based constitutive model involving material plasticity and grain refinement is developed based on both slip and twinning mechanisms and successfully implemented in a finite-element (FE) analysis with multiple cutting passes to predict the microstructure evolution by nanocrystalline grain refinement and other improvement of the surface integrity in the cryogenic machining of AZ31B Mg alloy. With a more quantitative assessment, the FE model results are further discussed for grain refinement, changes in microhardness, residual stresses, and slip/twinning mechanism with the apparent SPD taking place due to rapid cryogenic cooling.",

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author = "Ninggang Shen and Hongtao Ding and Zhengwen Pu and Jawahir, {I. S.} and Tao Jia",

note = "Funding Information: The authors gratefully acknowledge the financial support provided for the part of the study carried out at the University of Iowa by the National Science Foundation under Grant No. EPS-1101284 and State Key Laboratory of Mechanical System and Vibration, Shanghai Jiao Tong University, China under Grant No. MSV201514. Publisher Copyright: Copyright {\textcopyright} 2017 by ASME.",

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AU - Jawahir, I. S.

AU - Jia, Tao

N1 - Funding Information: The authors gratefully acknowledge the financial support provided for the part of the study carried out at the University of Iowa by the National Science Foundation under Grant No. EPS-1101284 and State Key Laboratory of Mechanical System and Vibration, Shanghai Jiao Tong University, China under Grant No. MSV201514. Publisher Copyright: Copyright © 2017 by ASME.

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AB - The use of magnesium (Mg) alloy has been continuously on the rise with numerous expanded application in transportation/aerospace industries due to their lightweight and other areas, such as biodegradable medical implants. It was shown recently that machining can be used to improve the functional performance of Mg-based products/components, such as corrosion resistance, through engineered surface integrity. In this paper, the behavior of AZ31B Mg alloy in cryogenic machining was discussed firstly. The surface integrity can be significantly improved by introducing the ultrafine grained (UFG) layer due to the severe plastic deformation (SPD) effect during cryogenic machining. The mechanisms of microstructure evolution and plastic deformation were analyzed based on the experimental findings in literature. A physics-based constitutive model involving material plasticity and grain refinement is developed based on both slip and twinning mechanisms and successfully implemented in a finite-element (FE) analysis with multiple cutting passes to predict the microstructure evolution by nanocrystalline grain refinement and other improvement of the surface integrity in the cryogenic machining of AZ31B Mg alloy. With a more quantitative assessment, the FE model results are further discussed for grain refinement, changes in microhardness, residual stresses, and slip/twinning mechanism with the apparent SPD taking place due to rapid cryogenic cooling.

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Enhanced Surface Integrity from Cryogenic Machining of AZ31B Mg Alloy: A Physics-Based Analysis with Microstructure Prediction

Abstract

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Keywords

ASJC Scopus subject areas

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