A method for evaluation of potential machinability correlated with material properties between different batches of material

Paper in proceeding, 2011

When producing parts from different batches of material, it is important to be able depict how material composition and other relevant material characteristics can affect the outcome of the machining process. This study presents a method for analysing and identifying variables in the material specification that could have the greatest impact on the machinability of the work material. The materials-related issues derived are summarised in a material property profile, called the potential machinability. The potential machinability is examined in terms of five material characteristics of the work material; ductility, strain hardening, thermal conductivity, yield strength, and abrasiveness. These properties are predicted for given material specification by using the materials modelling software JMatPro. An important advantage is that material properties can be calculated for high temperatures as well as for higher strain rates than those at normal tensile testing. The approach also admits material and process parameters to be varied individually, which is difficult or expensive in industrial processes. The transfer functions of the relations between material properties versus composition parameters, process parameters and their interaction was built with design of experiment varying simulation input parameters in order to derive metamodels of the individual material property. The meta-models are combined to the aggregated machinability prediction concept visualized in the form of polar diagrams.