Machinability of ferrous and non-ferrous alloys
Machinability is defined as the ease with which a specific material can be machined. It is generally assessed using various indicators such as tool life, tool wear, chip-breakability, cutting forces, material removal rate and surface finish. The interactions between the tool and the workpiece material are complex and can change the microstructural properties of the workpiece material. Even small variations in the type and amounts of workpiece micro-constituents can have a significant impact in machining, specifically on tool life. Several initiatives at MCR have been dedicated to better understanding these complex tool-workpiece interactions. This demands a multidisciplinary approach, which includes customized, sensor-based machining experiments, in-depth characterisation of workpiece materials and worn tools, and modelling and simulation of tribological phenomena on worn surfaces.
Researchers involved
- Dr. Amir Malakizadi, Chalmers
- Dr. Philipp Hoier, Chalmers
- M.Sc. Charlie Salame, Chalmers
- Dr. Ahmet Semih Ertürk, Chalmers
- Prof. Peter Krajnik, Chalmers
- Prof. Ragnar Larsson, Chalmers
- Prof. Lars Nyborg, Chalmers
- Prof. Uta Klement, Chalmers
Surface integrity in machining
The surface properties of a machined part have a significant impact on its performance during use, particularly for demanding applications in the aerospace, automotive and bearing industries. Surface damage, a poor surface roughness, residual stresses or sub-layer deformation can adversely affect the part’s fatigue life. This surface quality is closely related to the cutting-edge geometry, tool wear, and cutting, cooling and lubrication conditions during machining. A better understanding of the thermo-mechanical loads transferred to the machined and ground surfaces, combined with in-depth and multi-scale characterisation of surfaces, provides essential guidelines in meeting the targeted performance of the machined parts. MCR has led numerous initiatives in this area, particularly in machining and grinding of steels and titanium alloys.
Researchers involved
- Dr. Philipp Hoier, Chalmers
- Dr. Amir Malakizadi, Chalmers
- Prof. Uta Klement, Chalmers
- Prof. Lars Nyborg, Chalmers
- Prof. Peter Krajnik, Chalmers
Multi-scale modelling and simulation
Modelling and simulation play an important role in improving our understanding of the tribological conditions at the tool-workpiece interface. They are used in the prediction of tool performance and in-process optimization. This requires a multi-faceted approach. Atomic-scale simulations using Density Functional Theory (DFT) and thermodynamic simulations (CALPHAD) provide vital information about the micro-constituents and their interactions with the tool material. Finite Element (FE) and semi-analytical simulation of the cutting process enable the estimation of tribological parameters and thermo-mechanical loads on the tool surfaces. The integration of these modelling approaches provides a unique opportunity to develop fundamental physics-based approaches for modelling and simulation of tool wear. MCR has led several initiatives on a wide range of workpiece and tool materials.
Researchers involved
- Dr. Amir Malakizadi, Chalmers
- Dr. Philipp Hoier, Chalmers
- M.Sc. Charlie Salame, Chalmers
- Dr. Ahmet Semih Ertürk, Chalmers
- Prof. Peter Krajnik, Chalmers
- Prof. Ragnar Larsson, Chalmers