Effect of near-surface residual stress and microstructure modification from machining on the fatigue endurance of a tool steel

F. Ghanem, H. Sidhom, C. Braham, Michael E. Fitzpatrick

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Abstract

This study concerns the effect of machining on the fatigue life of an EN X155CrMoV12 tool steel (SAE J438b), with regard to the generation of near-surface residual stress and microstructural modification of the machined surface. Two possible methods for machining tool steels were compared: electro-discharge machining (EDM), a high energy density process, and milling, a more conventional cutting process. Particular attention was given to characterization of the surface roughness, microstructure, and residual stress, using a combination of microstructural analysis, crack observation, scanning electron microscopy (SEM), x-ray diffraction (XRD), and chemical composition changes by energy-dispersive x-ray. A decrease of around 35% in the fatigue limit was observed for the EDM samples, compared with the milled samples. This was attributed to a tensile residual stress state after EDM, combined with significant phase transformation and hydrogen embrittlement. The milled surfaces showed no microstructural transformation or surface cracking and contained compressive residual stresses, all of which contributed to an improved fatigue resistance.
Original languageEnglish
Pages (from-to)631-639
JournalJournal of Materials Engineering and Performance
Volume11
Issue number6
DOIs
Publication statusPublished - Dec 2002

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Tool steel
Electric discharge machining
Residual stresses
Machining
Durability
Fatigue of materials
Microstructure
X rays
Hydrogen embrittlement
Milling (machining)
Compressive stress
Tensile stress
Diffraction
Surface roughness
Phase transitions
Cracks
Scanning electron microscopy
Chemical analysis

Bibliographical note

This paper is not available on the repository

Keywords

  • Characterization and Evaluation of Materials
  • Materials Science
  • Tribology
  • Corrosion and Coatings
  • Quality Control
  • Reliability
  • Safety and Risk
  • Engineering Design

Cite this

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title = "Effect of near-surface residual stress and microstructure modification from machining on the fatigue endurance of a tool steel",
abstract = "This study concerns the effect of machining on the fatigue life of an EN X155CrMoV12 tool steel (SAE J438b), with regard to the generation of near-surface residual stress and microstructural modification of the machined surface. Two possible methods for machining tool steels were compared: electro-discharge machining (EDM), a high energy density process, and milling, a more conventional cutting process. Particular attention was given to characterization of the surface roughness, microstructure, and residual stress, using a combination of microstructural analysis, crack observation, scanning electron microscopy (SEM), x-ray diffraction (XRD), and chemical composition changes by energy-dispersive x-ray. A decrease of around 35{\%} in the fatigue limit was observed for the EDM samples, compared with the milled samples. This was attributed to a tensile residual stress state after EDM, combined with significant phase transformation and hydrogen embrittlement. The milled surfaces showed no microstructural transformation or surface cracking and contained compressive residual stresses, all of which contributed to an improved fatigue resistance.",
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T1 - Effect of near-surface residual stress and microstructure modification from machining on the fatigue endurance of a tool steel

AU - Ghanem, F.

AU - Sidhom, H.

AU - Braham, C.

AU - Fitzpatrick, Michael E.

N1 - This paper is not available on the repository

PY - 2002/12

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N2 - This study concerns the effect of machining on the fatigue life of an EN X155CrMoV12 tool steel (SAE J438b), with regard to the generation of near-surface residual stress and microstructural modification of the machined surface. Two possible methods for machining tool steels were compared: electro-discharge machining (EDM), a high energy density process, and milling, a more conventional cutting process. Particular attention was given to characterization of the surface roughness, microstructure, and residual stress, using a combination of microstructural analysis, crack observation, scanning electron microscopy (SEM), x-ray diffraction (XRD), and chemical composition changes by energy-dispersive x-ray. A decrease of around 35% in the fatigue limit was observed for the EDM samples, compared with the milled samples. This was attributed to a tensile residual stress state after EDM, combined with significant phase transformation and hydrogen embrittlement. The milled surfaces showed no microstructural transformation or surface cracking and contained compressive residual stresses, all of which contributed to an improved fatigue resistance.

AB - This study concerns the effect of machining on the fatigue life of an EN X155CrMoV12 tool steel (SAE J438b), with regard to the generation of near-surface residual stress and microstructural modification of the machined surface. Two possible methods for machining tool steels were compared: electro-discharge machining (EDM), a high energy density process, and milling, a more conventional cutting process. Particular attention was given to characterization of the surface roughness, microstructure, and residual stress, using a combination of microstructural analysis, crack observation, scanning electron microscopy (SEM), x-ray diffraction (XRD), and chemical composition changes by energy-dispersive x-ray. A decrease of around 35% in the fatigue limit was observed for the EDM samples, compared with the milled samples. This was attributed to a tensile residual stress state after EDM, combined with significant phase transformation and hydrogen embrittlement. The milled surfaces showed no microstructural transformation or surface cracking and contained compressive residual stresses, all of which contributed to an improved fatigue resistance.

KW - Characterization and Evaluation of Materials

KW - Materials Science

KW - Tribology

KW - Corrosion and Coatings

KW - Quality Control

KW - Reliability

KW - Safety and Risk

KW - Engineering Design

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JF - Journal of Materials Engineering and Performance

SN - 1059-9495

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