Influence of cutting edge geometry on tool wear performance in interrupted hard turning

2015 ◽  
Vol 19 ◽  
pp. 129-134 ◽  
Author(s):  
C.E.H. Ventura ◽  
J. Köhler ◽  
B. Denkena
Keyword(s):  
Tool Wear ◽  
Hard Turning ◽  
Cutting Edge ◽  
Wear Performance ◽  
Edge Geometry

Effect of Cutting-Edge Geometry and Workpiece Hardness on Surface Residual Stresses in Finish Hard Turning of AISI 52100 Steel

1999 ◽  
Author(s):  
Jeffrey D. Thiele ◽  
Shreyes N. Melkote ◽  
Roberta A. Peascoe ◽  
Thomas R. Watkins
Keyword(s):  
Residual Stresses ◽  
Hard Turning ◽  
Cutting Edge ◽  
Phase Changes ◽  
Edge Geometry ◽  
Surface Residual Stresses ◽  
Aisi 52100 ◽  
High Feed ◽  
Aisi 52100 Steel ◽  
Finish Hard Turning

Abstract An experimental investigation was conducted to determine the effects of tool cutting-edge geometry and workpiece hardness on surface residual stresses for finish hard turning of through-hardened AISI 52100 steel. Polycrystalline cubic boron nitride (PCBN) inserts with representative types of edge geometry including “up-sharp” edges, edge hones, and chamfers, were used as the cutting tools in this study. This study shows that tool edge geometry is highly influential with respect to surface residual stresses, which were measured using x-ray diffraction. In general, compressive surface residual stresses in the axial and circumferential directions were generated by large edge hone tools, for longitudinal turning operations. Residual stresses in the axial and circumferential directions generated by small edge hone tools are typically more tensile than stresses produced by large edge hone tools. Microstructural analysis shows that thermal effects are significant at high feed rates, based on the presence of phase changes on the workpiece surface. At high feed rates, compressive stresses correlate with continuous white layers and tensile stresses correlate with over-tempered regions on the surface of the workpiece. Mechanical effects play a larger role at low feed rates, where phase changes are not observed to a significant degree. For these cases, large edge hone tools generally produce more compressive values of residual stress than small edge hone tools.

Effect of Cutting-Edge Geometry and Workpiece Hardness on Surface Residual Stresses in Finish Hard Turning of AISI 52100 Steel

1999 ◽  
Vol 122 (4) ◽  
pp. 642-649 ◽  
Author(s):  
Jeffrey D. Thiele ◽  
Shreyes N. Melkote ◽  
Roberta A. Peascoe ◽  
Thomas R. Watkins
Keyword(s):  
Residual Stresses ◽  
Hard Turning ◽  
Cutting Edge ◽  
Edge Geometry ◽  
Surface Residual Stresses ◽  
Aisi 52100 ◽  
Aisi 52100 Steel ◽  
Finish Hard Turning ◽  
Hardness Values ◽  
Compressive Residual Stresses

An experimental investigation was conducted to determine the effects of tool cutting-edge geometry (edge preparation) and workpiece hardness on surface residual stresses for finish hard turning of through-hardened AISI 52100 steel. Polycrystalline cubic boron nitride (PCBN) inserts with representative types of edge geometry including “up-sharp” edges, edge hones, and chamfers were used as the cutting tools in this study. This study shows that tool edge geometry is highly influential with respect to surface residual stresses, which were measured using x-ray diffraction. In general, compressive surface residual stresses in the axial and circumferential directions were generated by large edge hone tools in longitudinal turning operations. Residual stresses in the axial and circumferential directions generated by large edge hone tools are typically more compressive than stresses produced by small edge hone tools. Microstructural analysis shows that thermally-induced phase transformation effects are present at all feeds and workpiece hardness values with the large edge hone tools, and only at high feeds and hardness values with the small edge hone tools. In general, continuous white layers on the workpiece surface correlate with compressive residual stresses, while over-tempered regions correlate with tensile or compressive residual stresses depending on the workpiece hardness. [S1087-1357(00)00304-X]

Edge Preparation on Cutting Force, Cutting Temperature and Tool Wear for Hard Turning

2014 ◽  
Vol 800-801 ◽  
pp. 424-429
Author(s):  
Pei Rong Zhang ◽  
Zhan Qiang Liu
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Hard Turning ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Cutting Edge ◽  
Crater Wear ◽  
Cutting Edge Preparation ◽  
Flank Face ◽  
Edge Preparation

The paper investigates the effects of cutting edge preparation on cutting force, cutting temperature and tool wear for hard turning. An optimized characterization approach is proposed and five kinds of cemented tools with different edge preparation are adopted in the simulations by DEFROM-2DTM. The results show that both the forces and cutting temperature on the rake face climb up and then declines with the increasing of factor K (Sγ/Sα). While the temperature on flank face decrease with the increasing of the factor K. When the cutting conditions are identical, flank wear reduces while crater wear exacerbates before easing with the increasing of the factor K. The simulation results will provide valuable suggestions for optimization of cutting edge preparation for hard turning in order to obtain excellent machining quality and longer tool life.

Effect of cutting edge geometry change due to tool wear on hole quality in drilling of carbon fiber reinforced plastics using advanced ceramic coated tools

2021 ◽  
pp. 095440622110235
Author(s):  
Mohammad Sayem Bin Abdullah ◽  
Dave Kim ◽  
Patrick Kwon ◽  
Tae-Gon Kim
Keyword(s):  
Carbon Fiber ◽  
Tool Wear ◽  
Flank Wear ◽  
Cutting Edge ◽  
Fiber Reinforced ◽  
Hole Quality ◽  
Cutting Edge Radius ◽  
Edge Geometry ◽  
Edge Radius ◽  
Carbon Fiber Reinforced

This paper aims to study the evolution of cutting edge geometry due to tool wear and discuss its impact on the hole quality of a carbon fiber reinforced plastic (CFRP) laminate. A drilling experiment was conducted using three types of twist drills: uncoated, BAM (AlMgB14) coated, and (AlCrSi/Ti)N nanocomposite coated tungsten carbide tools. After generating 120 holes, the uncoated drill had the largest cutting edge radius (∼36 µm), while the BAM coated drill had the most extensive flank wear (∼287 µm) among the three drills. This relatively rapid tool wear results in a reduction of average hole size and a considerable variation on the hole profiles. The worn drills with the cutting edge radius greater than 19.3 µm form the fiber pull-outs in not only the 135° plies but also the adjacent 45° and 90° plies from the cutting direction, creating deep void networks. This type of networked fiber pull-out damage was observed with the holes machined by the uncoated and BAM coated drills. The (AlCrSi/Ti)N coated drill, which experienced the least amount of flank wear and the least increase of cutting edge radius, generated consistently sized holes up to 120 holes. However, the relatively sharp (AlCrSi/Ti)N coated tool results in the higher arithmetic roughness average (Ra) and the maximum roughness height (Rz) values than the other tools due to the localized fiber pull-outs and the absence of severe matrix smearing.

Bohren von ausferritischem Gusseisen mit Kugelgraphit*/Drilling of austempered ductile iron – Impact of the cutting edge geometry on tool wear and machining result

2019 ◽  
Vol 109 (06) ◽  
pp. 496-504
Author(s):  
J. Hartig ◽  
B. Kirsch ◽  
J. C. Aurich
Keyword(s):  
Tool Wear ◽  
Tungsten Carbide ◽  
Ductile Iron ◽  
Cutting Edge ◽  
Machining Process ◽  
Austempered Ductile Iron ◽  
Edge Geometry ◽  
Cutting Edge Preparation ◽  
Edge Preparation ◽  
Homogeneous Preparation

Die Schneidkantenpräparation erlaubt ein gezieltes Anpassen des Werkzeugs an die Bearbeitungsaufgabe bei der Zerspanung. Homogene Präparationen können dabei entweder auf hohe Belastungen des Werkzeugs oder ein optimiertes Bearbeitungsergebnis im Sinne der Oberfläche ausgelegt werden. Mittels inhomogener Schneidkantenpräparation können die unterschiedlichen Anforderungen entlang des Eingriffs individuell in einem Werkzeug vereint werden. Im Beitrag wurden die Schneidkanten eines Wendeschneidplatten-Bohrwerkzeugs unterschiedlich homogen und inhomogen präpariert. Neben dem Werkzeugverschleiß wurde das Prozessergebnis beim Bohren von ausferritischem Gusseisen mit Kugelgraphit (ADI) 900 untersucht.   By using cutting edge preparation, tools can be tailored to the machining process. A homogeneous preparation can either be designed for high loads in the machining process or an optimized machining result on the surface. In contrast, an inhomogeneous cutting edge design can individually be designed to the machining task. In the article, the cutting edges of tungsten carbide indexable inserts were prepared homogeneous and inhomogeneous. Tool wear and machining result during drilling austempered ductile iron (ADI) 900 was investigated.

Effect of feed rate, workpiece hardness and cutting edge on subsurface residual stress in the hard turning of bearing steel using chamfer+hone cutting edge geometry

2005 ◽  
Vol 394 (1-2) ◽  
pp. 238-248 ◽  
Author(s):  
Jiang Hua ◽  
Rajiv Shivpuri ◽  
Xiaomin Cheng ◽  
Vikram Bedekar ◽  
Yoichi Matsumoto ◽  
...  
Keyword(s):  
Residual Stress ◽  
Feed Rate ◽  
Hard Turning ◽  
Bearing Steel ◽  
Cutting Edge ◽  
Edge Geometry
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