Influence of cutting tool constitutive parameters on residual stresses induced by hard turning

2008 ◽  
Vol 4 (1) ◽  
pp. 39 ◽  
Author(s):  
Joel Rech ◽  
Christophe Claudin
Keyword(s):  
Residual Stresses ◽  
Hard Turning ◽  
Cutting Tool ◽  
Constitutive Parameters

Surface Roughness and Cutting Force Components Evaluation in Hard Turning by Differently Shaped Cutting Tools

2016 ◽  
Vol 862 ◽  
pp. 26-32 ◽  
Author(s):  
Michaela Samardžiová
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Hard Turning ◽  
Cutting Tool ◽  
Single Point ◽  
Machining Process ◽  
Tool Geometry ◽  
Machined Surface ◽  
Cutting Force Components ◽  
Force Components

There is a difference in machining by the cutting tool with defined geometry and undefined geometry. That is one of the reasons of implementation of hard turning into the machining process. In current manufacturing processes is hard turning many times used as a fine finish operation. It has many advantages – machining by single point cutting tool, high productivity, flexibility, ability to produce parts with complex shapes at one clamping. Very important is to solve machined surface quality. There is a possibility to use wiper geometry in hard turning process to achieve 3 – 4 times lower surface roughness values. Cutting parameters influence cutting process as well as cutting tool geometry. It is necessary to take into consideration cutting force components as well. Issue of the use of wiper geometry has been still insufficiently researched.

scholarly journals Artificial neural network based tool wear estimation on dry hard turning processes of AISI4140 steel using coated carbide tool

2017 ◽  
Vol 65 (4) ◽  
pp. 553-559 ◽  
Author(s):  
D. Rajeev ◽  
D. Dinakaran ◽  
S.C.E. Singh
Keyword(s):  
Neural Network ◽  
Artificial Neural Network ◽  
Tool Wear ◽  
Hard Turning ◽  
Cutting Tool ◽  
Carbide Tool ◽  
Online Tool ◽  
Coated Carbide Tool ◽  
Tool Wear Estimation ◽  
Coated Carbide

AbstractNowadays, finishing operation in hardened steel parts which have wide industrial applications is done by hard turning. Cubic boron nitride (CBN) inserts, which are expensive, are used for hard turning. The cheaper coated carbide tool is seen as a substitute for CBN inserts in the hardness range (45–55 HRC). However, tool wear in a coated carbide tool during hard turning is a significant factor that influences the tolerance of machined surface. An online tool wear estimation system is essential for maintaining the surface quality and minimizing the manufacturing cost. In this investigation, the cutting tool wear estimation using artificial neural network (ANN) is proposed. AISI4140 steel hardened to 47 HRC is used as a work piece and a coated carbide tool is the cutting tool. Experimentation is based on full factorial design (FFD) as per design of experiments. The variations in cutting forces and vibrations are measured during the experimentation. Based on the process parameters and measured parameters an ANN-based tool wear estimator is developed. The wear outputs from the ANN model are then tested. It was observed that as the model using ANN provided quite satisfactory results, and that it can be used for online tool wear estimation.

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.

Cutting Tool Failure and Surface Finish Analysis in Pulsating MQL-Assisted Hard Turning

2020 ◽  
Vol 20 (4) ◽  
pp. 1274-1291
Author(s):  
Soumikh Roy ◽  
Ramanuj Kumar ◽  
Ashok Kumar Sahoo ◽  
Amlana Panda
Keyword(s):  
Surface Finish ◽  
Hard Turning ◽  
Cutting Tool ◽  
Tool Failure

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.

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]

scholarly journals Forces in hard turning of 51CrV4 with wiper cutting tool

2006 ◽  
Vol 11 (5) ◽  
pp. 501-506 ◽  
Author(s):  
Xinfeng He ◽  
Su Wu ◽  
Kratz Hubert
Keyword(s):  
Hard Turning ◽  
Cutting Tool

Research on the Residual Stresses in Cold-Formed Hat-Shaped Section

2012 ◽  
Vol 204-208 ◽  
pp. 934-938
Author(s):  
Hua Chen Liu ◽  
Feng Zhao
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Cutting Tool ◽  
Electrical Discharge Machining ◽  
Stress Measurement ◽  
Strain Gauges ◽  
Test Results ◽  
Antiseptic Treatment ◽  
Experimental Findings ◽  
Shaped Section

In the paper,the electrical discharge machining(EDM) technique was used to cut strips for cold-formed residual stress measurement of hat-shaped section.After adjusting the electrolyte ratio,designing specific the cutting tool and improving the methodof antiseptic treatment,the test results improved significantly. Electrical resistance strain gauges with EDM cutting technique were used to establish the magnitude and distribution of the residual stresses in cold-formed hat-shaped section.Based on the experimental findings, an idealized distribution pattern of the residual stress in cold-formed hat-shaped section is presented.

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