Residual stress reductions of carbide cutting tools through applying pulsed magnetic field and coupled electromagnetic field – mechanism analysis and comparison study

Zhong, Fu and Wang, Jie and Zhang, Qianwen and Huang, Jigang and Wang, Wei and Xu, Jie and Huang, Kunlan and Qin, Yi (2022) Residual stress reductions of carbide cutting tools through applying pulsed magnetic field and coupled electromagnetic field – mechanism analysis and comparison study. The International Journal of Advanced Manufacturing Technology, 121 (7-8). 4757–4775. ISSN 1433-3015 (https://doi.org/10.1007/s00170-022-09434-3)

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Abstract

The residual stress reductions of metals enabled by external field treatments are of high industrial significance, such as pulsed magnetic treatment (PMT) and coupled electromagnetic treatment (CET). There still exist sophisticated issues regarding process comparison and mechanism. In the present work, both the PMT and the CET were used to reduce the residual stress in P10 carbide tools. Besides residual stress measurements and microscopic observations of dislocations in the tested tools, a new model for modelling dislocation interactions in the treated tools was developed to reveal more complex mechanisms of the microstructural changes induced by the external fields. The results obtained with the X-ray diffraction method demonstrated a 30% stress reduction with the PMT and a 65% reduction with the CET. The dislocation morphology observed with a Transmission Electron Microscope was examined on their characteristics, quantity, and distribution. It was suggested that the WC phase with the dislocation of multiple quantities and wide distribution could be obtained easily through the CET. Deformation displacements and directions, internal stresses and volume strains, calculated using a transient 3D model with COMSOL (Multiphysics software), were compared. It was quantitatively confirmed that the internal stress produced both the PMT and the CET could force the dislocation to move. Compared with the PMT, there was a mutation phenomenon of the stress magnitude and direction during the CET, which was more conducive to the dislocation multiplication and dislocation interaction. The proposed Opposite Sign Parallel Dislocation Interaction Model also showed that the interactions between dislocations could effectively reduce the lattice distortion at the severe distortion area of the dislocations. The study showed that the residual stress could be effectively reduced by the evenly enhanced dislocation stretching and compression asymmetry after dislocation multiplication.

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