Phase transformations during machining of AISI52100 hardened steel

Samar ARFAOUIa, Farhat ZEMZEMIb, Zoubeir TOURKIc

Laboratoire Mécanique de Sousse (LMS),Ecole Nationale D’ Ingénieurs de Sousse
(ENISO),Sousse,Tunisia,
a
arfaoui.samar@gmail.com
b
fzemzemi@gmail.com
c
zbrtourki@gmail.com

Abstract –Hard machining of steels is often known by the formation of an undesirable white layer
(WL) on the surface of the work piece .The formation of this WL can be attributed to microstructure
changes such as phase transformations and grain refinement. The purpose of this study is to develop a
finite element model (FEM) able to predict phase transformations with dependence on the variation of
temperature during machining. 2D orthogonal cutting of AISI 52100 hardened steel was simulated
under dominant cutting conditions that enhance phase transformation. The model presents the phase
compositions and the evolution of the volume fraction related to the modified structure on machined
surface .

Keywords: Orthogonal cutting / Phase transformation / FEM-simulation / AISI52100/ Hard turning.

Hammamet, 23-25 March 2015, Tunisia 1

The 6th International Congress Design and Modelling of Mechanical Systems CMSM’2015
1 Introduction
Surface integrity of the hardened bearing steel AISI
52100 (62HRC) is a major concern for industries
because of its impact for product performance and
fatigue life of the component. Recent works
confirmed that residual stress -which are an
important indicator for surface integrity- are
affected by microstructure changes generated
during machining [1] .This fact make the necessity
to develop a finite element model to predict the
relationship between cutting conditions and
microstructure changes of machined surface.
The origins of white layer during machining are
attributed to three main theories [2]: severe plastic
deformation, rapid heating and quenching, and
surface reaction with the environment. Grain Figure1. TRC diagram for AISI 52100 steel [4]
refinement is related to the first theory whereas
phase transformation is related to the second theory 3 Numerical model
[1], In fact high cutting speed enhances the
quantity of energy provided from friction and 3.1Model geometry and limits conditions
plastic deformation. This energy is converted into
heat and this leads to high temperature in the
machined surface which makes the possibility of 2D orthogonal cutting was simulated using
austenitic phase transformation occurrence, then Abaqus/Explicit v6.10 coupled to a user-defined
self quenching leads to low temperature which subroutine VUMAT written in Compact Digital
makes the possibility of martensitic structure. Phase FORTRAN which implements the transformation
transformation is determined experimentally under kinetics. The test was run using the following
an optical microscope by the appearance of a white condition:
layer in the subsurface of a few thick microns. [3] (i) A cutting speed Vc=3 m/s and a feed rate
f=0.2mm
(ii) A four-node plane strain thermally coupled
2 Phase transformation kinetics quadrilateral elements of CPE4RT mesh type
(iii) The tool is forbidden from movement in all
The initial structure of AISI52100(62HRC) is a directions while the work piece is animated by a
tempered martensite, then during machining the velocity movement equal to Vc
phase nature of the machined surface is determined (iv)At the beginning of simulation all nodes are
by a comparison between the current temperature T maintained to the room temperature T=25°C
and the temperature transformation ,this can be (v)The geometry of work piece has a length
more described with the TRC diagram in figure 1. L=10mm and a width l =3mm, the tool has a cutting
In fact, if the temperature in the element exceeds edge radius r =0.02 mm and a rake angle=0°
the As (austenite start temperature) the structure is
transformed instantly into austenite then if
temperature drops below Ms (Marteniste start
temperature) the austenite is transformed into 3.2Consitutive law
martensite .
The fraction of formed martensite fm is calculated The tool is modeled purely elastic while the work
from the following equation proposed by Koinisten piece is modeled as elastic and plastic .The
and Marburger : plasticity of the AISI 52100 steel was described
using Vonmises criterion and Johnson Cook law
𝑓𝑚 =1-exp(-0.011(𝑀𝑠 -T)) (1) which defines the flow stress 𝜎 through the
equivalent plastic strain 𝜀 ,the strain rate 𝜀̇, and
Ferrite, cementite and bainite structure are not the temperature T :
allowed to be formed because the heating and the
cooling rate during machining are estimated to 𝜀̇ 𝑇−25 𝑚
𝜎(𝜀, 𝜀̇,T)=[𝐴 + 𝐵𝜀 𝑛 ] [1 + 𝐶𝐿𝑛( ̇ )] [1 − ( ) ] (2)
𝜀0 𝑇𝑚 −25
10E06 K/s which avoids the formation of those
phases [3].
All physical properties employed in this study are
given in tables 1 and 2.

Hammamet, 23-25 March 2015, Tunisia 2

 The friction behavior between the tool and the work
piece is described through Coulomb friction using a
value of coefficient friction  equal to 0.2.

Table 2: Johnson -Cook constants [5]

A(MPa) B(Mpa) n C m 𝜀0̇

688.17 150.82 0.336 0.042 2.778 0.01

Figure3.Martensitic transformation during machining

Table 1. Physical properties [5] 5 Conclusion

Workpiece Tool This study presented an FEM simulation in
Properties AISI52100 Low CBn orthogonal cutting including the influence of
(62HRC) thermal behaviour in phase transformations of an
Density(kg/m3) 7827 4370 AISI 52100 hardened steel .The material structure
Young’s modulus 210000 600000 is linked to heat treatment produced during
(MPa) machining. The model presented the evolution of
Poisson’s ratio 0.27 0.17 the fraction of formed phases in the machined
Specific heat(J/kg°C) 458 750 surface.
Thermal 46.6 44
conductivity(W/mk) This work will be extended with involving
phenomena related to martensitic transformation
such as transformation plasticity and then the model
4 Results will be used to predict residual stress.
Figure 2 shows the phase transformation from a
tempered martensite into austenite, the red regions
6 References
describe the presence of an amount of austenite
equal to 100% while the blue regions describe the [1] D.Umbrello, Influence of material
tempered martensite (initial structure), this microstructure changes on surface integrity in hard
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the part of just machined surface, this is explained .(2011) 54: 887-898
by the fact that the current temperature in those [2] B.-J Grrifiths,White layer formations at
zones reaches As due to the contact between the machined surfaces and their relationship to white
tool and work piece which generates heat. Figure 3 layer formations at worn surfaces,1985,pp.165-171
describes the evolution of martensite phase which is
more important in regions which are more cooled [3] H.Ding, Y.-C.Shin, Multi-physics modelling
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degradation is related to the different percentage of in hard turning,J of Materials Processing Technol
martensite. 213 (2013) 877–886
Figures 2 and 3 confirm that only the sub surface
and the chip are concerned to phase transformations [4] A.Hor, Simulation physique des conditions
and the bulk material conserves its initial structure. thermomécanique de forgeage et d’usinage-
caractérisation et modélisation de la rhéologie et de
l’endommagement, PhD thesis ,Paris Tec, France ,
2011
[5] A.Ramesh,S.-N.Melkote,Modeling of white
layer formation under thermally dominant
conditions in orthogonal machining of hardened
AISI 52100 steel,Int.J of MachineTools and
Manufacture.48(2008) 402-414

Figure2.Austenitic transformation during machining

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