Mechanism and machinability in novel electroplastic-assisted grinding ductile iron

doi:10.1007/s40436-024-00533-w

Abstract

Abstract: Owing to the hard brittle phase organization in their matrixes, brittle materials are prone to the formation of pits and cracks on machined surfaces under extreme grinding conditions, which severely affect the overall performance and service behavior of machined parts. Based on the electroplastic effect of pulsed currents during material deformation, this study investigates electroplastic-assisted grinding with different electrical parameters (current, frequency, and duty cycle). The results demonstrate that compared to conventional grinding, the pulsed current can significantly decrease the surface roughness (S_a) of the workpiece and reduce surface pits and crack defects. The higher the pulsed current, the more pronounced the improvement in the surface quality of the workpiece. Compared to traditional grinding, when the pulsed current is 1 000 A, S_a decreases by 46.4%, and surface pit and crack defects are eliminated. Under the same pulse-current amplitude and frequency conditions, the surface quality continues to improve as the duty cycle increases. When the duty cycle is 75%, S_a reaches a minimum of 0.749 μm. However, the surface quality is insensitive to the pulsed-current frequency. By investigating the influence of pulsed electrical parameters on the surface quality of brittle material under grinding conditions, this study provides a theoretical basis and technical support for improving the machining quality of hard, brittle materials.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00533-w

Key words: Electroplasticity, Grinding machining, Brittle material, Pulse parameters, Surface quality

Jia-Hao Liu, Dong-Zhou Jia, Chang-He Li, Yan-Bin Zhang, Ying Fu, Zhen-Lin Lv, Shuo Feng. Mechanism and machinability in novel electroplastic-assisted grinding ductile iron[J]. Advances in Manufacturing, 2025, 13(1): 245-263.

TrendMD

References

[1] Chen M, Zhao Q, Dong S et al (2005) The critical conditions of brittle-ductile transition and the factors influencing the surface quality of brittle materials in ultra-precision grinding. J Mater Process Technol 168:75-82
[2] Zhang X, Yang L, Wang Y et al (2020) Mechanism study on ultrasonic vibration assisted face grinding of hard and brittle materials. J Manuf Process 50:520-527
[3] Antwi E, Liu K, Wang H et al (2018) A review on ductile mode cutting of brittle materials. Front Mech Eng-Prc 13:251-263
[4] Liang Z, Tian M, Wang Q et al (2016) Simulation investigation on crack initiation and propagation in ultrasonic assisted grinding of ceramics material. Acta Armamentarii 37:895-902
[5] Debras C, Dubar L, Dubar M et al (2019) Fracture energy based approach for cemented carbides grain debonding. Int J Mech Sci 161:105038. https://doi.org/10.1016/j.ijmecsci.2019.105038
[6] Dang JQ, An QL, Lian GH et al (2021) Surface modification and its effect on the tensile and fatigue properties of 300M steel subjected to ultrasonic surface rolling process. Surf Coat Tech 422:127566. https://doi.org/10.1016/j.surfcoat.2021.127566
[7] Dimitrov N, Liu Y, Horstemeyer M (2022) Electroplasticity: a review of mechanisms in electro-mechanical coupling of ductile metals. Mech Adv Mater Struc 29:705-716
[8] Biesuz M, Saunders T, Ke D et al (2021) A review of electromagnetic processing of materials (EPM): heating, sintering, joining and forming. J Mater Sci Technol 69:239-272
[9] Liu JH, Jia DZ, Fu Y et al (2023) Electroplasticity effects: from mechanism to application. Int J Adv Manuf Tech 131:3267-3286
[10] Xiang S, Zhang X (2019) Dislocation structure evolution under electroplastic effect. Mater Sci Eng A 761:138026. https://doi.org/10.1016/j.msea.2019.138026
[11] Fan Y, Fan H, Hao Z (2023) Effect of pulsed current on plastic deformation of Inconel 718 under high strain rate and high temperature conditions. J Alloy Compd 943:169150. https://doi.org/10.1016/j.jallcom.2023.169150
[12] Li X, Zhu Q, Hong Y et al (2022) Revealing the pulse-induced electroplasticity by decoupling electron wind force. Nat Commun 13:6503. https://doi.org/10.1038/s41467-022-34333-2
[13] Jeong H, Kim M, Park J et al (2017) Effect of pulsed electric current on dissolution of Mg17Al12 phases in as-extruded AZ91 magnesium alloy. Mater Sci Eng A 684:668-676
[14] Qian L, Zhan L, Zhou B et al (2021) Effects of electroplastic rolling on mechanical properties and microstructure of low-carbon martensitic steel. Mater Sci Eng A 812:141144. https://doi.org/10.1016/j.msea.2021.141144
[15] Xiao X, Xu S, Sui D et al (2021) The electroplastic effect on the deformation and twinning behavior of AZ31 foils during micro-bending tests. Mater Lett. 288: 129362. https://doi.org/10.1016/j.matlet.2021.129362
[16] Egea AJS, Rojas HAG, Celentano DJ et al (2016) Mechanical and metallurgical changes on 308L wires drawn by electropulses. Mater Design 90:1159-1169
[17] Tang G, Zhang J, Zheng M et al (2000) Experimental study of electroplastic effect on stainless steel wire 304L. Mater Sci Eng A 281:263-267
[18] Wang R, Xu Z, Jiang Y et al (2023) Design high-performance AZ31 ultrathin strip through multi-pass electroplastic rolling without off-line annealing. Mater Sci Eng A 862:144510. https://doi.org/10.1016/j.msea.2022.144510
[19] Xie H, Dong X, Ai Z et al (2016) Experimental investigation on electrically assisted cylindrical deep drawing of AZ31B magnesium alloy sheet. Int J Adv Manuf Tech 86:1063-1069
[20] Zhao L, Chen G, Liu J et al (2023) Effect of pulse current parameters on electroplastically assisted dry cutting performance of W93NiFe alloy. Int J Adv Manuf Tech. https://doi.org/10.1007/s00170-022-10762-7
[21] Hameed S, Gonzalez RHA, Sánchez EAJ et al (2016) Electroplastic cutting influence on power consumption during drilling process. Int J Adv Manuf Tech 87:1835-1841
[22] Ulutan D, Pleta A, Mears L (2015) Electrically-assisted machining of titanium alloy Ti-6Al-4V and nickel-based alloy IN-738: an investigation. Int Manuf Sci Eng Conf 56826:V001T02A013. https://doi.org/10.1115/MSEC2015-9465
[23] Shao Z, Li G, Liu W et al (2023) Advance in the research of electric pulse-assisted cutting. Int J Adv Manuf Tech 127:2107-2123
[24] Ruszkiewicz BJ, Grimm T, Ragai I et al (2017) A review of electrically-assisted manufacturing with emphasis on modeling and understanding of the electroplastic effect. J Manuf Sci Eng 139:110801. https://doi.org/10.1115/1.4036716
[25] Zhang ZY, Wang X, Meng FN et al (2022) Origin and evolution of a crack in silicon induced by a single grain grinding. J Manuf Process 75:617-626
[26] Zhao WD, Liu DX, Zhang XH et al (2020) The effect of electropulsing-assisted ultrasonic nanocrystal surface modification on the microstructure and properties of 300M steel. Surf Coat Tech 397:125994. https://doi.org/10.1016/j.surfcoat.2020.125994
[27] Shao ZH, Li GH, Liu WJ et al (2023) Advance in the research of electric pulse-assisted cutting. Int J Adv Manuf Tech 127(5):2107-2123
[28] Xu Z, Jiang T, Huang J et al (2022) Electroplasticity in electrically-assisted forming: process phenomena, performances and modelling. Int J Mach Tool Manu 175:103871. https://doi.org/10.1016/j.ijmachtools.2022.103871
[29] Daniel DM, Ávila BN, Garcia MV et al (2020) Grinding comparative between ductile iron and austempered ductile iron under CBN wheel combined to abrasive grains with high and low friability. Int J Adv Manuf Tech 109:2679-2690
[30] Jia DZ, Li CH, Liu JH et al (2023) Prediction model of volume average diameter and analysis of atomization characteristics in electrostatic atomization minimum quantity lubrication. Friction 11:2107-2131
[31] Song Y, Li C, Zhou Z et al (2024) Nanobiolubricant grinding: a comprehensive review. Adv Manuf. https://doi.org/10.1007/s40436-023-00477-7
[32] Wang H, Chen L, Liu D et al (2015) Study on electropulsing assisted turning process for AISI 304 stainless steel. Mater Sci Tech-Lond 31:1564-1571
[33] Li BK, Ding WF, Zhu YZ et al (2023) Design and grindability assessment with cup shaped electroplated CBN wheel grinding turbine disc slots of powder metallurgy superalloy FGH96. Chin J Aeronaut. https://doi.org/10.1016/j.cja.2023.12.030
[34] Zhang J, Li C, Zhang Y et al (2018) Temperature field model and experimental verification on cryogenic air nanofluid minimum quantity lubrication grinding. Int J Adv Manuf Tech 97:209-228
[35] Liu M, Li C, Zhang Y et al (2022) Analysis of grinding mechanics and improved grinding force model based on randomized grain geometric characteristics. Chin J Aeronaut 36(7):160-193
[36] Cui X, Li C, Zhang Y et al (2023) Comparative assessment of force, temperature, and wheel wear in sustainable grinding aerospace alloy using biolubricant. Front Mech Eng 18:3. https://doi.org/10.1007/s11465-022-0719-x
[37] Donaghy-Spargo C, Horsfall A (2019) Transient skin effect in power electronic applications. J Eng 17:3696-3700
[38] Zhang Y, Li C, Jia D et al (2015) Experimental evaluation of the lubrication performance of MoS₂/CNT nanofluid for minimal quantity lubrication in Ni-based alloy grinding. Int J Mach Tool Manu 99:19-33
[39] Dambatta YS, Li C, Yang M et al (2023) Grinding with minimum quantity lubrication: a comparative assessment. Int J Adv Manuf Tech 128:955-1014
[40] Yang M, Kong M, Li C et al (2023) Temperature field model in surface grinding: a comparative assessment. Int J Extreme Manuf. 5: 042011. https://doi.org/10.1088/2631-7990/acf4d4
[41] Tian Z, Chen X, Xu X (2020) Molecular dynamics simulation of the material removal in the scratching of 4H-SiC and 6H-SiC substrates. Int J Extreme Manuf 2:95-109
[42] Noreyan A, Amar JG (2008) Molecular dynamics simulations of nanoscratching of 3C SiC. Wear 265:956-962
[43] Hao L, Li W, Qian L et al (2023) Investigation of the heat energy and multi-level load on subsurface fatigue damage evolution via multi-scale method. Fatigue Fract Eng M 46:2830-2844
[44] Simonetto E, Bruschi S, Ghiotti A (2019) Electroplastic effect on AA1050 plastic flow behavior in H24 tempered and fully annealed conditions. Procedia Manuf 34:83-89
[45] Okazaki K, Kagawa M, Conrad H (1980) An evaluation of the contributions of skin, pinch and heating effects to the electroplastic effect in titatnium. Mat Sci Eng 45:109-116
[46] Zhang H, Zhang X (2020) Uniform texture in Al-Zn-Mg alloys using a coupled force field of electron wind and external load. J Mater Sci Technol 36:149-159
[47] Li Q, Chen X, Chang G et al (2008) Effect of pulse current on the annealing structure and property of spherical graphite iron. J Univ Sci Technol B 30:854-857
[48] Stolyarov V, Calliari I, Gennari C (2021) Features of the interaction of plastic deformation and pulse current in various materials. Mater Lett 299:130049. https://doi.org/10.1016/j.matlet.2021.130049
[49] Yan A, Zhang H, Deng B et al (2024) Analytical modeling of subsurface damage in laser-assisted machining of metal matrix composites based on the reinforcement fracture probability. J Manuf Process 109:300-312
[50] Dang JQ, Wang CG, Wang HG et al (2023) Deformation behavior and microstructure evolution of 300M ultrahigh strength steel subjected to high strain rate: an analytical approach. J Mater Res Technol 25:812-831