Experimental and computational investigation of machining processes for functionally graded materials

Biermann, D.1, a; Menzel, A.2; Bartel, T.2; Höhne, F.1, b; Holtermann, R.2; Ostwald, R.2, c; Sieben, B.1, d; Tiffe, M.1, e; Zabel, A.1, f

Institut für Spanende Fertigung, Technische Universität Dortmund, Baroper Str. 303, 44227 Dortmund
Institut für Mechanik, Technische Universität Dortmund, Leonhard-Euler-Str. 5, 44227 Dortmund

a) biermann@isf.de; b) hoehne@isf.de; c) richard.ostwald@udo.edu; d) sieben@isf.de; e) tiffe@isf.de; f) zabel@isf.de


Experiments on dry face turning of functionally graded heat treatable steel are conducted. The workpieces have a hardened zone of approx. 60 HRC and a non-hardened zone of approx. 30 HRC. PCBN tools are used with different feeds, cutting speeds and depths of cut. Measurements of residual stresses in the surface layer reveal compressive stresses in the hardened zone and tensile stresses in the non-hardened zone. These experimental observations are compared with the results of representative simulations of the cutting process. A large-deformation thermo-elastoviscoplastic material model is used and the geometry of the cutting tool is precisely reflected by the finite element discretisation. To predict the overall response, an adaptive remeshing scheme and full thermo-mechanical coupling is accounted for. Moreover, measured residual stresses are incorporated as initial conditions within the simulation.


Finite element method (FEM), Turning, Residual stresses, Functionally graded materials, Remeshing


Procedia Engineering, 19 (2011), S. 22-27, doi: 10.1016/j.proeng.2011.11.074