Towards the multi-scale simulation of martensitic phase-transformations: An efficient post-processing approach applied to turning processes

This work presents an efficient finite element based scheme for the prediction of process properties and especially the material condition of workpiece surfaces after turning. This is achieved by using a database generated with the help of a micromechanically motivated material model - capable of simulating interactions of phase transitions and plasticity - for the efficient post-processing of a macroscopic thermo-mechanically coupled finite element simulation of the turning process. This modelling technique is applied to the martensitic part of a functionally graded workpiece which is produced by thermo-mechanically controlled forging processes. Those workpieces provide locally varying material conditions, which are tailored to the later application. The resulting pre-products have to be turned in order to achieve the desired final workpiece geometry and surfaces. Such processes strongly affect material properties such as hardness and ductility. A deterioration of the functionality of the gradation, i.e. the martensitic surface properties, may occur by generation of residual tensile principal stresses which can occur accompanied by white layer formation. These deteriorations can be avoided by adjusting the process parameters appropriately. Especially the cutting speed is supposed to bean a low level (v(c) < 80 m/min) to avoid thermally driven formation of a white layer and the generation of tensile residual stresses. It is shown how finite element simulations can give insight into the material interactions and thereby facilitate the support of the process parameter adjustment in order to support efficient and reliable part production in industrial applications.(C) 2014 Elsevier B.V. All rights reserved.