Numerical and experimental validation of microstructural changes and hardness variation in milling of ASTM A216 WCB carbon steel

• Published in: Journal of manufacturing processes 2024-09, Vol.125, p.432-441
• Main Authors: Caruso, Serafino, Izquierdo Rodriguez, David, Ambrogio, Giuseppina, Gagliardi, Francesco
• Format: Article
• Language: English
• Subjects: FE modelling; Grain size; Machining; Microstructural changes; Milling; Surface integrity
• ISSN: 1526-6125; 2212-4616
• DOI: 10.1016/j.jmapro.2024.07.061

Surface characteristics of machined components, such as microstructure and hardness, play a key role to be competitive in the current industrial scenario because they strongly influence the functional performance of the engineered products. These characteristics can be affected by the manufacturing processes. Accurate numerical models have been developed to predict property surface changes during machining. In the present work, metallurgical changes during full face milling of the ASTM A216 WCB carbon steel have been modelled by a customised 3D finite element (FE) model with a physics-based constitutive law for the material behaviour. A user subroutine has been implemented in the FE code to simulate changes induced by the machining on the processed surface and in depth. The model was calibrated and experimentally validated at varying of the main process variables. The outcomes showed the effectiveness of the proposed FE model in predicting average max temperature trends (an average discrepancy of 5 % and maximum one of 9 % were obtained), grain size and machining affected layer changes (the error was generally contained under the 10 % for all the investigated cases) and microhardness variations (an average discrepancy of 7 % and a maximum one of 9 % were reached) at varying of the process parameters. Finally, the model has allowed understanding the evolution of microstructural changes during machining and their influence on the material behaviour through the prediction of the dynamic recrystallized grain size and dislocation density evolution. [Display omitted] •Metallurgical changes on the processed material during full face milling were modelled.•A model with a physics-based material constitutive law was set and experimentally validated.•A user subroutine was implemented to simulate changes induced by the machining process.•The model effectiveness was tested in predicting temperature, grain size and microhardness variations.•The model was able to predict dynamic recrystallized grain size and dislocation density evolution.