Modeling of microstructural workpiece rim zone modifications during hard machining

Surface integrity determines, among other factors such as tool material and wear, the chemical composition and microstructure of the workpiece material as well as selected cutting parameters, the performance of machined parts. The aggressive nature of the cutting process influences the surface integrity and causes altered microstructure on the workpiece surface. Most popular example is the White Layer formation, which reduces the fatigue resistance of components. To study the influence of cutting parameters on White Layer thickness for a steel of grade AISI 4140, in this paper, a physics-based dislocation density-based model is implemented to predict the White Layer formation under the assumption of dynamic recrystallization. As a material model, a modified coupled damage mechanics model based on Johnson–Cook is implemented, which considers in comparison to the original one, damage induced softening using damage initiation and fracture indicators as well as strengthening mechanisms through grain refinement and dislocation damping at high strain rates. Dry orthogonal cutting is modeled via Coupled-Eulerian–Lagrangian method in Abaqus/Explicit. The developed model is validated based on experimental data regarding grain size and White Layer thickness. The model overestimated the grain size on the machined workpiece rim zone by a factor of 2–4, while the White Layer thickness was predicted with an error of max. 0.36 μm.