Possibilities of the Generation of Hardened Steel Parts With Defined Topographic Characteristics of the Machined Surfaces

2015 ◽  
Vol 137 (1) ◽  
Author(s):  
Wit Grzesik ◽  
Krzysztof Żak
Keyword(s):  
Hard Turning ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Roughness Parameter ◽  
Hardened Steel ◽  
Roughness Parameters ◽  
Turning Operations ◽  
Topographic Characteristics ◽  
Grinding Operations ◽  
Hard Cutting

The main objective of the comparison of precision hard cutting and abrasive processes in terms of the surface texture is to facilitate the decision whether to possibly replace grinding operations by hard turning with low feed rates. In this study, hard turning operations with Cubic Boron Nitride (CBN) cutting tools and grinding operations using electrocorundum Al2O3 and CBN wheels were performed in order to generate surfaces with the Sa roughness parameter of about 0.2 μm. 3D roughness parameters and the frequency, fractal and motif characteristics were analyzed.

scholarly journals Cutting Mechanics and Surface Finish for Turning with Differently Shaped CBN Tools

2017 ◽  
Vol 64 (3) ◽  
pp. 347-357
Author(s):  
Krzysztof Żak
Keyword(s):  
Surface Roughness ◽  
Hard Turning ◽  
Cutting Parameters ◽  
Material Distribution ◽  
Roughness Parameters ◽  
Turning Operations ◽  
Cutting Power ◽  
Finish Turning ◽  
Corner Radius ◽  
Relevant Material

Abstract In this paper, the basic cutting characteristics such as cutting forces, cutting power and its distribution, specific cutting energies were determined taking into account variable tool corner radius ranging from 400 to 1200 µm and constant cutting parameters typical for hard turning of a hardened 41Cr4 alloy steel of 55±1 HRC hardness. Finish turning operations were performed using chamfered CBN tools. Moreover, selected roughness profiles produced for different tool corner radius were compared and appropriate surface roughness parameters were measured. The measured values of Ra and Rz roughness parameters are compared with their theoretical values and relevant material distribution curves and bearing parameters are presented.

Mikrofräswerkzeuge mit Schneiden aus cBN*/Micro-cutting tools with cBN cutters

2018 ◽  
Vol 108 (11-12) ◽  
pp. 773-777
Author(s):  
E. Uhlmann ◽  
J. Polte ◽  
M. Polte ◽  
Y. Kuche ◽  
H. Wiesner
Keyword(s):  
Surface Roughness ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
High Strength ◽  
Hardened Steel ◽  
Micro Milling ◽  
Geometric Accuracy ◽  
Micro Cutting ◽  
Core Technology ◽  
Milling Tools

Die Mikrozerspanung ist eine Kerntechnologie bei der Fertigung von Mikrospritzgussformen. Die hohen Ansprüche an die geometrische Genauigkeit und Oberflächenrauheit erfordern den Einsatz hochfester Werkstoffe. Jedoch unterliegen aktuelle Fräswerkzeuge bei der Mikrozerspanung einem hohen Verschleiß. Einen Lösungsansatz bietet der erfolgreich in der Makrozerspanung eingesetzte Schneidstoff kubisch-kristallines Bornitrid (cBN). Ziel der Untersuchungen war es daher, detaillierte Informationen zur Bearbeitung von gehärtetem Stahl mit cBN-Mikrofräswerkzeugen bereitstellen zu können.   Micro-cutting is a core technology for producing micro-injection moulds. High demands on geometric accuracy and surface roughness require high-strength materials. However, current milling tools for micro-cutting suffer from excessiv tool wear. A solution is offered by cutting materials based on cubic Boron Nitride (cBN), which have been used successfully in macro-machining. This article contains detailed information on the machining of hardened steel with micro-milling tools and cutting edges made of cBN.

High Precision Cutting and High Speed Interrupted Cutting of Hardened Steel With PCBN Tools

1999 ◽  
Author(s):  
Katsuhito Yoshida ◽  
Satoru Kukino ◽  
Takashi Harada ◽  
Tomohiro Fukaya ◽  
Junichi Shiraishi ◽  
...  
Keyword(s):  
High Precision ◽  
High Speed ◽  
New Technologies ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Hardened Steel ◽  
Precision Machining ◽  
Polycrystalline Cubic Boron Nitride ◽  
Interrupted Cutting ◽  
Pcbn Tools

Abstract PCBN (Polycrystalline Cubic Boron Nitride) cutting tools have become very familiar in the industries for cutting hardened steel parts and the demand for PCBN tools is growing rapidly. One of the reasons for this is the trend of replacing grinding processes with cutting. Although the trend of processing is to use more cutting, there still remains grinding in many processing fields. High precision machining and high speed interrupted machining have been such fields. In this study it has been verified that a novel cutting method can be applied to high precision machining with the smoothness of Rz 0.8 μm and that a new PCBN has sufficient reliability against tool failure in high speed (< 250m/min) interrupted cutting. Thus cutting has become applicable to those machining and the trend of replacement of grinding with cutting will be enhanced. Those new technologies will be introduced in this report.

Research of Technology of Cutting Hardened Steel in HSM

2011 ◽  
Vol 338 ◽  
pp. 701-705
Author(s):  
Xiao Jun Zhu ◽  
Wen Sheng Xia
Keyword(s):  
High Speed ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Tool Material ◽  
Main Tool ◽  
Hardened Steel ◽  
Detection Methods ◽  
Tool Geometry ◽  
High Speed Milling ◽  
Coated Cemented Carbide

The key technology of the cutter that cutting hardened steel was researched by high speed milling machining method. At first ,three cutting elements of high speed milling machining was narratived, and we can obtain the principle of selection of parameters of cutting velocity, feed per tooth, longitudinal cutting depth and cutting width of axial, etc. With HSM ,we discussed the performance and selection points of tool material of coated cemented carbide, ceramic, cubic boron nitride , synthetic diamond and so on, and obtained the effect of the main tool geometry for the cutting process in HSM. The second, it analysised type and reason of damage of high speed cutting tools, and introduced three detection methods of tools. Finally, it was summarized and concluded.

Application of CBN Cutting Tools in Hard Turning and Tool Wear

2013 ◽  
Vol 690-693 ◽  
pp. 2022-2025
Author(s):  
Hai Dong Zhao ◽  
Li Bao An ◽  
Pei Qing Yang ◽  
Ye Geng
Keyword(s):  
Tool Wear ◽  
Hard Turning ◽  
Manufacturing Industry ◽  
Metal Cutting ◽  
Elevated Temperatures ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Tool Material ◽  
Specific Strength ◽  
Strength And Stiffness

Considerable research has been directed towards discovering new engineering materials for various applications. As a superhard material, Cubic Boron Nitride (CBN) has been developed and applied to engineering for several tens of years. Due to its high specific strength and stiffness as well as good creep, fatigue and wear resistance at elevated temperatures, CBN has been widely used as cutting tool material in manufacturing industry. In this paper, the preparation and characteristics of CBN are introduced. As hard turning has been more and more employed in recent years as an advanced metal cutting technique, the application of CBN cutting tools in hard turning is presented based on the literature, and in particular, the main wear mechanisms of CBN tools in hard turning are summarized, owing to the significant influence of tool wear on the tool life and product quality.

Laboratory Experiment of New Cutting Materials in Milling Processes

2014 ◽  
Vol 611 ◽  
pp. 467-471 ◽  
Author(s):  
Igor Vilček ◽  
Jozef Kováč ◽  
Jaroslava Janeková
Keyword(s):  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
High Hardness ◽  
Hardened Steel ◽  
Production Costs ◽  
Machining Processes ◽  
Hard Materials ◽  
Removal Processes ◽  
Conventional Machining ◽  
Cutting Tool Materials

The development of manufacturing technology is mostly given by economics, environmental trends and the development of cutting materials and machine tools. Manufacturing is a significant part of the worldwide economy. Machining (material removal processes) represents major part of production costs. This paper yield inquiries into the hard and precise milling with a focus on force effects in experimental machining, tool wear and final surface qualities (roughness, micro hardness). The precision machining of hardened steel differs from conventional machining in terms of the hardness of the workpiece materials and the cutting tool materials that are required. Hard materials are characterized by high hardness (> 45 HRC) and abrasiveness. Machining processes require cutting tools of much higher hardness and also higher resistance of the abrasive wear. Recently developed cubic boron nitride (CBN) and coated sintered carbides cutting tools are considered to have the ability of cutting such as steel. CBN cutting tools show good performance during machining of the hardened steel because of their hot hardness and good fracture toughness.

Characterization of Surface Integrity Produced by Sequential Dry Hard Turning and Ball Burnishing Operations

2014 ◽  
Vol 136 (3) ◽  
Author(s):  
Wit Grzesik ◽  
Krzysztof Żak
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Hard Turning ◽  
Cubic Boron Nitride ◽  
High Strength ◽  
Lower Surface ◽  
Roughness Parameters ◽  
Ball Burnishing ◽  
Machining Processes ◽  
Finish Hard Turning

This paper presents the state of surface integrity produced on hardened-high strength 41Cr4 steel after hard machining and finish ball burnishing. Surfaces machined by sequential machining processes were characterized using 2D and 3D surface roughness parameters. Moreover, detailed functionality of the generated surfaces was performed using a set of 3D functional roughness parameters. Among the characteristics of the surface layer, its microstructure, the distribution of microhardness and the residual stresses were determined. This investigation confirms that ball burnishing allows producing surfaces with lower surface roughness and better service properties than those generated by cubic boron nitride (CBN) finish hard turning operations.

Cutting Force Model Prediction Considering Cutting Edge Parameters Base on Genetic Algorithm

2011 ◽  
Vol 188 ◽  
pp. 166-170
Author(s):  
Yu Wang ◽  
L.Q. Wang ◽  
Y.F. Li ◽  
Yuan Sheng Zhai ◽  
X.L. Liu
Keyword(s):  
Genetic Algorithm ◽  
Cutting Force ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Cutting Edge ◽  
Force Model ◽  
Cutting Force Model ◽  
Shear Slip ◽  
Hard Cutting

During precise hard cutting, back cutting depth and feed rate are relatively small. Study on the influence of PCBN (Polycrystalline Cubic Boron Nitride) cutting tools edge (chamfer edge or cutting edge radius) on cutting force is important. As the effect of cutting edge on mechanism of shear slip plane is very complicated, so to study the effect of consider cutting edge parameters and cutting parameters by genetic algorithm on cutting force, to build up cutting force model of precise hard cutting. It is feasible to predict cutting force by genetic algorithm with experiment.

scholarly journals TRIBOLOGY AND TOPOGRAPHY OF HARD MACHINED SURFACES

2021 ◽  
pp. 49-59
Author(s):  
Viktor Molnár
Keyword(s):  
Hard Turning ◽  
High Accuracy ◽  
Hard Machining ◽  
Roughness Parameters ◽  
Industrial Practice ◽  
Oil Retention ◽  
3D Surface Roughness ◽  
Topographic Characteristics ◽  
2D And 3D ◽  
Topographic Parameters

In machining automotive industrial parts by hard machining procedures, the topographic characteristics of high accuracy surfaces have high importance. In this paper 2D and 3D surface roughness features of gear bores machined by hard turning and grinding are demonstrated. The 3D roughness parameters, which are considered as more exact than the 2D parameters, were compared to the 2D ones, which are used more widely in industrial practice. The analyzed machining procedure versions were ranked based on the topographic parameters determining the tribological (wear and oil-retention capability) characteristics of the different surfaces.

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