Surface Finish for a Case of Continuous and Interrupted OD Hard Turning

Manufacturing ◽  
2003 ◽  
Author(s):  
Radu Pavel ◽  
Keith Sinram ◽  
Dana Combs ◽  
Jim Pillar ◽  
Ioan Marinescu
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
Hard Turning ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Regression Equations ◽  
Nose Radius ◽  
Interrupted Cutting ◽  
New Findings ◽  
Significant Difference

Hard turning is the process to watch in many industries, as it is a perfect candidate for the actual trends toward automation and flexible manufacturing. However, there are still many possible conjunctures created by different geometries or materials of the workpieces versus different types of cutting tools with effect on workpiece surface quality, tool wear, machine tool vibrations, etc. These insufficiently explored combinations make manufacturers hesitate to adopt hard turning as a finishing process. This paper brings new findings concerning the effect of cutting parameters and tool nose radius variations on surface finish as a result of continuous and interrupted hard turning. The considered workpieces are a camshaft made of AISI 1117 steel at 62 HRC for continuous cutting, and a spline shaft made of AISI 1137 steel at 48 HRC for interrupted cutting. Two types of PcBN cutting tools are used for both types of component parts. The investigation highlights the differences between the ideal, geometrically determined, surface roughness Ra and the experimental results, as well as the differences recorded between the continuous and interrupted cutting situations. The factorial experimentation technique was employed taking the resulting surface rughness (Ra) as a response variable. The influence of tool wear was finally considered in the analysis of the predicted values of roughness obtained through characteristic regression equations. A significant difference of roughness evolution versus tool wear was recorded for the continuous and interrupted surfaces. The analysis was completed based on profilometry and light interferometry measurements as well as optical and SEM microscopy observations.

scholarly journals ENERGY-BASED CHARACTERIZATION OF PRECISION HARD MACHINING USING PARTIALLY WORN CBN CUTTING TOOLS

2019 ◽  
Vol 19 (2) ◽  
pp. 55-62 ◽  
Author(s):  
Wit GRZESIK ◽  
Berend DENKENA ◽  
Krzysztof ZAK
Keyword(s):  
Tool Wear ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Point Of View ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Additional Tool ◽  
Variable Feed Rate ◽  
Wear Tests

This paper highlights the performance of precision hard turning with CBN cutting tools from energy point- of-view with additional tool wear effect. For this purpose several wear tests were performed during which the tool nose wear VBC and the corresponding changes of component forces Fc, Ff and Fp were continuously measured. Based on the measured forces and geometrical characteristic of the uncut layer, specific cutting and ploughing energy were determined for several combinations of cutting parameters. Consequently, changes of energy consumption resulting from tool wear evolution for variable feed rate, depth of cut and tool nose radius were presented.

Correlation Between Friction and Wear of Cubic Borone Nitride Cutting Tools in Precision Hard Machining

2015 ◽  
Vol 138 (3) ◽  
Author(s):  
Wit Grzesik ◽  
Berend Denkena ◽  
Krzysztof Żak ◽  
Thilo Grove ◽  
Benjamin Bergmann
Keyword(s):  
Friction Coefficient ◽  
Tool Wear ◽  
Friction And Wear ◽  
Hard Turning ◽  
Cutting Tools ◽  
Depth Of Cut ◽  
Hard Machining ◽  
Nose Radius ◽  
Friction Forces ◽  
Wear Tests

In this paper, the contribution of tool wear to friction was determined for precision hard turning using Cubic Borone Nitride (CBN) cutting tools. The tool nose wear VBC and the corresponding changes of component forces Fc, Ff, and Fp resulting from tool wear evolution were continuously measured during wear tests. Based on the mechanics of nonorthogonal cutting, the normal and friction forces acting on rake and flank faces were calculated for all measuring points, and as a result, relevant changes of the friction coefficient were determined. Additionally, friction changes resulting from tool wear under different feed rate, depth of cut, and tool nose radius were discussed in terms of the plowing energy produced by the tool nose.

CBN Tool Wear Modeling in Finish Hard Turning

Manufacturing ◽  
2003 ◽  
Author(s):  
Yong Huang ◽  
Steven Y. Liang
Keyword(s):  
Tool Wear ◽  
Hard Turning ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Tool Geometry ◽  
Wear Volume ◽  
Wear Rates ◽  
Cbn Tool ◽  
Finish Hard Turning

The cubic boron nitride (CBN) cutting tools are commonly used for single point turning of hardened materials. The wear behavior and tool life of CBN cutters are important issues in order for hard turning to be a viable technology in view of the high cost of CBN cutting tools and the cost of down-time for tool change. The objective of this study is to develop a methodology to model the rate of CBN tool wear on both the flank and rake faces. The model can serve both as a basis to guide the design of CBN tool geometry and to optimize cutting parameters in finish hard turning. First, the kinematics, stress distribution, and temperature variation on the tool flank and rake faces are formulated. Subsequently, the wear volume loss is modeled as functions of cutting temperature, stress, and other process information based on the consideration of main wear mechanisms of abrasion, adhesion, and diffusion. Then, flank/crater wear rates are predicted in terms of tool/work material properties and cutting configuration. Finally, based on the calibrated wear coefficients in independent tests, the proposed models are experimentally validated in finish turning hardened 52100 bearing steel using a low CBN content insert. The model predictions agree with the measurements in terms of the behavior of stable growths of wear land and crater. The adhesion is found to be the dominating wear mechanism over the range of cutting parameters examined.

Effects of Insert Nose Radius and Processing Cutting Parameter on the Surface Roughness of Aisi 316 Stainless Steel

2010 ◽  
Vol 447-448 ◽  
pp. 51-54
Author(s):  
Mohd Fazuri Abdullah ◽  
Muhammad Ilman Hakimi Chua Abdullah ◽  
Abu Bakar Sulong ◽  
Jaharah A. Ghani
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Surface Finish ◽  
Feed Rate ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Aisi 316

The effects of different cutting parameters, insert nose radius, cutting speed and feed rates on the surface quality of the stainless steel to be use in medical application. Stainless steel AISI 316 had been machined with three different nose radiuses (0.4 mm 0.8 mm, and 1.2mm), three different cutting speeds (100, 130, 170 m/min) and feed rates (0.1, 0.125, 0.16 mm/rev) while depth of cut keep constant at (0.4 mm). It is seen that the insert nose radius, feed rates, and cutting speed have different effect on the surface roughness. The minimum average surface roughness (0.225µm) has been measured using the nose radius insert (1.2 mm) at lowest feed rate (0.1 mm/rev). The highest surface roughness (1.838µm) has been measured with nose radius insert (0.4 mm) at highest feed rate (0.16 mm/rev). The analysis of ANOVA showed the cutting speed is not dominant in processing for the fine surface finish compared with feed rate and nose radius. Conclusion, surface roughness is decreasing with decreasing of the feed rate. High nose radius produce better surface finish than small nose radius because of the maximum uncut chip thickness decreases with increase of nose radius.

Cutting Tool Wear and Mechanisms of Chip Formation During High-Speed Machining of Compacted Graphite Iron

2007 ◽  
Author(s):  
Niniza S. P. Dlamini ◽  
Iakovos Sigalas ◽  
Andreas Koursaris
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
Failure Criterion ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Tools ◽  
Compacted Graphite Iron ◽  
Crater Wear ◽  
Compacted Graphite ◽  
Cutting Speeds

Cutting tool wear of polycrystalline cubic boron nitride (PcBN) tools was investigated in oblique turning experiments when machining compacted graphite iron at high cutting speeds, with the intention of elucidating the failure mechanisms of the cutting tools and presenting an analysis of the chip formation process. Dry finish turning experiments were conducted in a CNC lathe at cutting speeds in the range of 500–800m/min, at a feed rate of 0.05mm/rev and depth of cut of 0.2mm. Two different tool end-of-life criteria were used: a maximum flank wear scar size of 0.3mm (flank wear failure criterion) or loss of cutting edge due to rapid crater wear to a point where the cutting tool cannot machine with an acceptable surface finish (surface finish criterion). At high cutting speeds, the cutting tools failed prior to reaching the flank wear failure criterion due to rapid crater wear on the rake face of the cutting tools. Chip analysis, using SEM, revealed shear localized chips, with adiabatic shear bands produced in the primary and secondary shear zones.

Designing and implementation of a novel online adaptive control with optimization technique in hard turning

2020 ◽  
pp. 095965182095219
Author(s):  
Vahid Pourmostaghimi ◽  
Mohammad Zadshakoyan
Keyword(s):  
Adaptive Control ◽  
Tool Wear ◽  
Hard Turning ◽  
Cutting Tool ◽  
Optimization Technique ◽  
Cutting Parameters ◽  
Numerical Control ◽  
Machining Process ◽  
Machining Parameters ◽  
Optimization Methodology

Determination of optimum cutting parameters is one of the most essential tasks in process planning of metal parts. However, to achieve the optimal machining performance, the cutting parameters have to be regulated in real time. Therefore, utilizing an intelligent-based control system, which can adjust the machining parameters in accordance with optimal criteria, is inevitable. This article presents an intelligent adaptive control with optimization methodology to optimize material removal rate and machining cost subjected to surface quality constraint in finish turning of hardened AISI D2 considering the real condition of the cutting tool. Wavelet packet transform of cutting tool vibration signals is applied to estimate tool wear. Artificial intelligence techniques (artificial neural networks, genetic programming and particle swarm optimization) are used for modeling of surface roughness and tool wear and optimization of machining process during hard turning. Confirmatory experiments indicated that the efficiency of the proposed adaptive control with optimization methodology is 25.6% higher compared to the traditional computer numerical control turning systems.

Reinforcement and Cutting Tools Interaction during MMC Machining - A Review

2018 ◽  
Vol 22 ◽  
pp. 47-54 ◽  
Author(s):  
Mukesh Chaudhari ◽  
M. Senthil Kumar
Keyword(s):  
Tool Wear ◽  
Metal Matrix Composites ◽  
Process Parameters ◽  
Surface Finish ◽  
Metal Matrix ◽  
Cutting Tools ◽  
Tool Geometry ◽  
Matrix Composites ◽  
Good Surface ◽  
Aerospace Medical

Aluminum based metal matrix composites (AMMC) have found its applications in the automobile, aerospace, medical, and metal industries due to their superior mechanical properties. Fabricated Aluminum based metal matrix composites require machining to improve the surface finish and dimensional tolerance. Machining should be accomplished by good surface finish by consuming lowest energy and less tool wear. This paper reviews the machining of Aluminum based metal matrix composites to investigate the effect of process parameters such as tool geometry, tool wear, surface roughness, chip formation and also process parameters.

Study on Tool Life and Tool Wear Mechanisms in Dry Cutting Pure Iron

2013 ◽  
Vol 770 ◽  
pp. 74-77 ◽  
Author(s):  
Jin Xing Kong ◽  
Liang Li ◽  
Dong Ming Xu ◽  
Ning He
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Wear Mechanisms ◽  
Pure Iron ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Cutting Condition ◽  
High Plasticity ◽  
Dry Cutting ◽  
Tool Wear Mechanisms

Pure iron is a kind of high plasticity and toughness material. In the process of cutting pure iron, the tool wear is very serious. In this paper, three kinds of cutting tools KC5010, K313 and 1105 are used in the cutting pure iron process and the tool wear tests in dry cutting condition with different cutting parameters have been carried out. According to the results, the tool wear mechanisms and tool life of three kinds of cutting tools have been compared and analyzed. It is concluded that the tool life of K313 is better than KC5010 and 1105 and the three kinds of tool mechanisms are primarily adhesion wear, diffusion wear and oxidation wear.

Tool Wear Characters in Micro-Milling of Fully Sintered ZrO2 Ceramics by Diamond Coated End Mills

2012 ◽  
Vol 723 ◽  
pp. 365-370 ◽  
Author(s):  
Rong Bian ◽  
Eleonora Ferraris ◽  
Jun Qian ◽  
Dominiek Reynaerts ◽  
Liang Li ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cutting Tools ◽  
Chemical Vapour ◽  
Cutting Parameters ◽  
Micro Milling ◽  
Machined Surface ◽  
Coated Tools ◽  
Machined Surface Quality ◽  
Coating Delamination ◽  
End Mills

This work presents an experimental investigation on micro-milling of fully sintered Zirconia (ZrO2) by diamond coated tools. The experiments were conducted on a Kern MMP 2522 micro-milling centre and WC micro end mills, diamond coated by chemical vapour deposition (CVD) and of stiff geometry were employed as cutting tools. The effects of cutting parameters and milling time on tool wear were investigated. The results revealed that the tool wear characters included diamond coating delamination and wear of substrate WC. Both cutting forces and machined surface quality were affected by tool wear with the progress of milling.

Sign in / Sign up

Export Citation Format

Share Document