PREDICTION AND INVESTIGATION OF SURFACE ROUGHNESS WHILE TURNING SG IRON WITH CUBIC BORON NITRIDE (CBN) AND TUNGSTEN CARBIDE INSERTS

2017 ◽  
Vol 41 (1) ◽  
pp. 129-141 ◽  
Author(s):  
K.M. Kumar ◽  
P. Hariharan
Keyword(s):  
Surface Roughness ◽  
Boron Nitride ◽  
Tungsten Carbide ◽  
Cubic Boron Nitride ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Spheroidal Graphite ◽  
Surface Model ◽  
Sg Iron ◽  
The Impact

This work compares the effect of cubic boron nitride (CBN) and multilayer (TiCN+Al2O3+TiN) coated tungsten carbide (WC) tools during the turning of spheroidal graphite (SG) nodular iron. Nodular irons have more ductility which is required in mechanical components that demand high fatigue resistance like crankshafts, cam shafts, bearing caps and clutch housings. The impact of various process parameters like the depth of cut, cutting speed and feed on the surface roughness (Ra) of SG iron is studied and optimized using the response surface model. The chip morphology is also discussed for evaluation of the quality of the turned surface. The experimental outcomes reveal that the WC tool offers a high surface finish at the optimal combination of the cutting speed at 102 meter/minute, feed at 0.051 millimeter/revolution and depth of cut at 0.5 millimeter and that, for the CBN insert, at 245 meter/minute of cutting speed, 0.051 millimeter/revolution of feed and 0.75 millimeter of depth of cut.

scholarly journals Technics Research on Polycrystalline Cubic Boron Nitride Cutting Tools Dry Turning Ti-6AL-4V Alloy Based on Orthogonal Experimental Design

2018 ◽  
Vol 142 ◽  
pp. 03002
Author(s):  
Yunhai Jia ◽  
Lixin Zhu
Keyword(s):  
Surface Roughness ◽  
Experimental Design ◽  
Boron Nitride ◽  
Feed Rate ◽  
Flank Wear ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Orthogonal Experimental Design ◽  
Polycrystalline Cubic Boron Nitride

Ti-6Al-4V components are the most widely used titanium alloy products not only in the aerospace industry, but also for bio-medical applications. The machine-ability of titanium alloys is impaired by their high temperature chemical reactivity, low thermal conductivity and low modulus of elasticity. Polycrystalline cubic boron nitride represents a substitute tool material for turning titanium alloys due to its high hardness, wear resistance, thermal stability and hot red hardness. For determination of suitable cutting parameters in dry turning Ti-6AL-4V alloy by Polycrystalline cubic boron nitride cutting tools, the samples, 300mm in length and 100mm in diameter, were dry machined in a lathe. The turning suitable parameters, such as cutting speed, feed rate and cut depth were determined according to workpieces surface roughness and tools flank wear based on orthogonal experimental design. The experiment showed that the cutting speed in the range of 160~180 m/min, the feed rate is 0.15 mm/rev and the depth of cut is 0.20mm, ideal workpiece surface roughness and little cutting tools flank wear can be obtained.

Study on Factors which Make CBN Insert can Turn S45C Steel Have Surface Roughness Less than Ra 0.4

2019 ◽  
Vol 805 ◽  
pp. 3-7
Author(s):  
Manus Sriswat ◽  
Kittipong Kimapong ◽  
Atthakorn Chanchana
Keyword(s):  
Surface Roughness ◽  
Contact Area ◽  
Cubic Boron Nitride ◽  
Cutting Speed ◽  
Medium Carbon Steel ◽  
Depth Of Cut ◽  
Grinding Process ◽  
Standard Type ◽  
Good Surface ◽  
Cylindrical Parts

Grinding process is necessary final process of making cylindrical parts with less than Ra 0.4 surface roughness. Generally we cannot obtain good surface quality without grinding process. As the experience of the authors, using CBN (Cubic Boron Nitride) insert to turning cylindrical parts could be obtained Ra 0.438 surface roughness. The surface roughness result is similar to ground parts. This result becomes the main focus of the study. Authors study to find out factors affecting CBN performance in turning with CBN to obtain less than Ra 0.4 surface roughness. According to the study, it was found that tool contact area allied to surface roughness. The experiment is turning S45C medium carbon steel under the following condition: Cutting speed is 300 m./min, Feed is 0.05 mm./rev and depth of cut is 0.1 mm. Experiment under the same condition in different contact area. Modify contact area of CBN insert to be 5,10,15,20 and 25 mm. and testing in order. CBN insert standard type contact area is 0 mm. Compare test results of modified CBN inserts with standard type result. The results of experiments were as follows: 1) Turning steel with CBN contact area 10 mm. was obtained Ra 0.456 surface roughness, 2) Turning steel with CBN contact area 15 mm. was obtained Ra 0.293 surface roughness, Thus less than Ra 0.4 surface roughness.

Optimization of tungsten carbide processing parameters for laser heating and ultrasonic vibration composite assisted cutting

2018 ◽  
Vol 233 (12) ◽  
pp. 4140-4153
Author(s):  
Feng Jiao ◽  
Ming-jun Zhang ◽  
Ying Niu
Keyword(s):  
Surface Roughness ◽  
Tungsten Carbide ◽  
Ultrasonic Vibration ◽  
Laser Heating ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machining Properties

Laser heating assisted cutting is a lucrative technique for machining difficult-to-machine materials such as tungsten carbide (YG20), which uses a high power laser to focally heat a workpiece before the material removal with traditional or innovative cutting tool. In the latter case, the application of ultrasonic vibration to the cutting edge was found to replace the continuous cutting mode to the interrupted one, it reduces the adhesion and entanglement of chips, improves the tool wear and surface roughness of the workpiece. The combination of laser heating assisted cutting and two-dimensional ultrasonic vibration cutting methods has been successfully applied by the authors of this paper for cutting of tungsten carbide (YG20). In this follow-up study, the proposed composite method is experimentally and theoretically verified. Through the mathematical model and simulation analysis, its advantages, including small cutting force, softening the effect and improved machining properties of the processed material (YG20) are corroborated. The dependencies between the laser power, cutting speed, depth of cut, and feed rate on the surface roughness are established via the response surface methodology. The genetic algorithm is applied to the optimization of machining parameters by setting the material removal rate as the object variable and surface roughness as a constraint variable. The results obtained strongly suggest that the optimized parameters improve the processing efficiency and furnish the required processing quality.

DEVELOPMENT OF SURFACE ROUGHNESS PREDICTION MODEL FOR HARD TURNING ON AISI D2 STEEL USING CUBIC BORON NITRIDE INSERT

2017 ◽  
Vol 80 (1) ◽  
Author(s):  
Amrifan Saladin Mohruni ◽  
Muhammad Yanis ◽  
Edwin Kurniawan
Keyword(s):  
Surface Roughness ◽  
Boron Nitride ◽  
Feed Rate ◽  
Hard Turning ◽  
Cubic Boron Nitride ◽  
Cutting Speed ◽  
Machining Parameters ◽  
Aisi D2 Steel ◽  
Aisi D2 ◽  
D2 Steel

Hard turning is an alternative to traditional grinding in the manufacturing industry for hardened ferrous alloy material above 45 HRC. Hard turning has advantages such as lower equipment cost, shorter setup time, fewer process steps, greater part geometry flexibility and elimination of cutting fluid. In this study, the effect of cutting speed and feed rate on surface roughness in hard turning was experimentally investigated. AISI D2 steel workpiece (62 HRC) was machined with Cubic Boron Nitride (CBN) insert under dry machining. A 2k-factorial design with 4 centre points as an initial design of experiment (DOE) and a central composite design (CCD) as augmented design were used in developing the empirical mathematical models. They were employed for analysing the significant machining parameters. The results show that the surface roughness value decreased (smoother) with increasing cutting speed. In contrary, surface roughness value increased significantly when the feed rate increased. Optimum cutting speed and feed rate condition in this experiment was 105 m/min and 0.10 mm/rev respectively with surface roughness value was 0.267 µm. Further investigation revealed that the second order model is a valid surface roughness model, while the linear model cannot be used as a predicted model due to its lack of fit significance.

Influence of Machining Parameters on Surface Topography of Cubic Boron Nitride at Rotary Ultrasonic Machining

2016 ◽  
Vol 686 ◽  
pp. 180-185 ◽  
Author(s):  
Marcel Kuruc ◽  
Martin Kusý ◽  
Vladimír Šimna ◽  
Jozef Peterka
Keyword(s):  
Surface Roughness ◽  
Boron Nitride ◽  
Feed Rate ◽  
Cubic Boron Nitride ◽  
Cutting Speed ◽  
Machining Parameters ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Hard And Brittle Materials ◽  
Advanced Machining

Poly-crystalline cubic boron nitride (PCBN) is one of the hardest known material. Therefore only advanced methods are able to treat such material. Advanced machining methods, proper for machining of hard and brittle materials (such as glass and ceramics) include rotary ultrasonic machining (RUM). This method should achieve high precision and low surface roughness (at least during machining of materials such as ceramics). Achievable roughness is affected by machined material and machining parameters. This contribution investigates influence of machining parameters, such as cutting speed and feed rate, on resultant surface roughness during machining of PCBN by rotary ultrasonic machining.

Precision Vertical Grinding of Cemented Tungsten Carbide Using CBN Wheels

2013 ◽  
Vol 303-306 ◽  
pp. 2481-2484
Author(s):  
Zhi Jian He ◽  
Xu Kun Liang
Keyword(s):  
Surface Roughness ◽  
Boron Nitride ◽  
Tungsten Carbide ◽  
Cubic Boron Nitride ◽  
Grinding Wheel ◽  
Precision Grinding ◽  
Grinding Parameters ◽  
Cbn Grinding Wheel ◽  
Important Significance ◽  
Cemented Tungsten Carbide

A set of precision vertical grinding experiment on WC-CO cemented tungsten carbide materials was carried out using cubic boron nitride (CBN) grinding wheel. Different grinding parameters such as rotation speeds of workpiece, feed rates and grinding depths were employed during precision vertical grinding. Surface roughness was measured for studying the grinding charateristics of WC-CO cemented tungsten carbide in this removal mode. Optimal grinding parameters were obtained by changing the process parameters. The research results have an important significance to improve grinding quality and efficiency for precision grinding cemented tungsten carbide materials.

scholarly journals Assessments of Process Parameters on Cutting Force and Surface Roughness during Drilling of AA7075/TiB2 In Situ Composite

Materials ◽  
2021 ◽  
Vol 14 (7) ◽  
pp. 1726
Author(s):  
S. Parasuraman ◽  
I. Elamvazuthi ◽  
G. Kanagaraj ◽  
Elango Natarajan ◽  
A. Pugazhenthi
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Basic Class ◽  
Tib2 Particles ◽  
The Impact ◽  
Loss Of Strength

Reinforced aluminum composites are the basic class of materials for aviation and transport industries. The machinability of these composites is still an issue due to the presence of hard fillers. The current research is aimed to investigate the drilling topographies of AA7075/TiB2 composites. The samples were prepared with 0, 3, 6, 9 and 12 wt.% of fillers and experiments were conducted by varying the cutting speed, feed, depth of cut and tool nose radius. The machining forces and surface topographies, the structure of the cutting tool and chip patterns were examined. The maximum cutting force was recorded upon increase in cutting speed because of thermal softening, loss of strength discontinuity and reduction of the built-up-edge. The increased plastic deformation with higher cutting speed resulted in the excess metal chip. In addition, the increase in cutting speed improved the surface roughness due to decrease in material movement. The cutting force was decreased upon high loading of TiB2 due to the deterioration of chips caused by fillers. Further introduction of TiB2 particles above 12 wt.% weakened the composite; however, due to the impact of the microcutting action of the fillers, the surface roughness was improved.

Research on the Surface Roughness of Dry Cutting Different Levels of Austempering Ductile Iron (ADI)

2011 ◽  
Vol 464 ◽  
pp. 496-500
Author(s):  
Xiao Hong Xue ◽  
Xu Hong Guo ◽  
Ting Ting Chen ◽  
Dong Dong Wan ◽  
Qiao Wang
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Isothermal Quenching ◽  
Dry Cutting ◽  
Quenching Temperature

Three cutting tools of different materials (ceramics CC6050, cubic boron nitride CB7025, carbide GC2025) are used for dry turning of 9 groups of ADI which heat-treated under different quenching time and quenching temperature. The surface roughness of ADI workpieces were tested after the finish turning at changed cutting parameters, and the influencing factors of surface quality were analysed. Results showed that the surface roughness values of all 9 groups of ADI workpieces obtained by CC6050 were the lowest and the surface quality was better at lower depth of cut ap and feed rate f with higher cutting speed vc . Meanwhile, the surface roughness was influenced by the isothermal quenching parameters of ADI workpieces significantly.

Evaluation of the Performance of CBN Tools When Turning Austempered Ductile Iron Material

2008 ◽  
Vol 130 (5) ◽  
Author(s):  
K. Aslantas ◽  
İ. Ucun ◽  
K. Gök
Keyword(s):  
Surface Roughness ◽  
Ductile Iron ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Salt Bath ◽  
Austempered Ductile Iron ◽  
Depth Of Cut ◽  
Tool Performance ◽  
Austempering Temperature

The study deals with the machinability properties of austempered ductile iron using cubic boron nitride cutting tools. To emphasize the role of the austempering process, ductile iron specimens were first austenitized in salt bath at 900°C for 60min, after which they were quenched in a salt bath at 250°C and 325°C for 60min. Machining tests were carried out at various cutting speeds under the constant depth of cut and the feed rate. Tool performance was evaluated based on the workpiece surface roughness and flank wear. The influence of the austempering temperature and cutting speed on the chip form was also studied. The results point out that the lower austempering temperature results in the increase in the cutting forces, while better surface roughness is attained.

Performance of Turning Steels by Using Polycrystalline Cubic Boron Nitride Cutting Tool

2013 ◽  
Vol 315 ◽  
pp. 146-150
Author(s):  
Mohd Zulhasyree Mohd Zulkifli Cheng ◽  
Yusri Yusof
Keyword(s):  
Surface Roughness ◽  
Cutting Tool ◽  
Cubic Boron Nitride ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Aisi 4140 ◽  
Roughness Analysis ◽  
Cutting Length ◽  
Aisi D2 ◽  
Steel Aisi

PCBN cutting tool is widely used in turning process and known as second best cutting tool after Diamond. This study investigates the suitability of PCBN cutting tool to cut variety types of steel. Experimental results for three major parameters which are cutting speed 150, 175 and 200 m/min, depth of cut 0.1, 0.2 and 0.3 mm, and feed 0.1, 0.2, and 0.3 mm/rev were converted into surface roughness analysis to look on the performance of PCBN to cut three different types of steels. The selected work materials of carbon steel AISI 1040, alloy steel AISI 4140 and tool steed AISI D2 were machined in dry tuning process with constant cutting length 50 mm and initial workpiece diameter 40 mm. At the end of this study, it is shown that higher cutting speed produced better surface roughness for AISI 1040 and AISI D2 but worsen the surface of AISI 4140. Low feed value is the most practical parameter to be used to produce fine surface finish using PCBN cutting tool. Fluctuate roughness value produced by increasing depth of cut use in turning parameters and no specific relationship can be concluded between depth of cut and surface roughness value.

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