Description
Intermetallic iron–aluminum (FeAl) has an excellent resistance against corrosion and abrasion, a low density as well as high specific strength compared to conventional steel. In addition, the raw materials and manufacturing costs of FeAl-alloys are relatively low. The machinability is challenging. Economical machining of FeAl-alloys is currently not possible because of high tool wear. The chip formation mechanisms in machining FeAlalloys are currently unknown. This study focuses on the influence of the material grain size on the thermomechanical processes during chip formation. A simultaneous measuring system for the determination of process forces, temperatures and chip formation in planing and orthogonal turning is presented. The chip formation mechanisms change with the grain transition and grain size. Decreasing grain sizes lead to the higher ductility in material Separation by favorable thermomechanical loads and reduced crack initiation. By using force data from monocrystalline machining a model is introduced, which predicts the force dynamics in machining of polycrystals.
