Using Pulse Laser Processing to Shape Cutting Edge of PcBN Tool for High-Precision Turning of Hardened Steel

2013 ◽  
Vol 7 (3) ◽  
pp. 337-344 ◽  
Author(s):  
Daisuke Suzuki ◽  
◽  
Fumihiro Itoigawa ◽  
Keiichi Kawata ◽  
Takashi Nakamura ◽  
...  
Keyword(s):  
High Precision ◽  
Laser Processing ◽  
Chemical Reactivity ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Surface Hardness ◽  
Hardened Steel ◽  
Cutting Edge ◽  
Precision Turning ◽  
Edge Sharpness

Polycrystalline Cubic Boron Nitride (PcBN) cutting tools have excellent characteristics, such as a high degree of hardness and low chemical reactivity, so they have the potential to replace the high precision grinding of hardened steel with high precision cutting. However, there are some problems inherent in so-called sintered materials, including low formability and unsteady wear. In order to solve these problems, pulsed laser processing is applied to shape a cutting edge. In this study, first PcBN cutting tools processed by lasers are adopted to the high-precision turning of hardened steel with 58HRC. As the result, these PcBN cutting tools provide a steady cutting state and a smoother finished surface. Second, in order to investigate these advantages of PcBN cutting tools processed by laser, individual requirements of the cutting tool are investigated: edge sharpness, surface quality including micro-defects, surface hardness, and friction coefficient. The results indicate that tools processed by laser have sharper edges and smoother, harder, and lowerfiction surfaces, compared to ground tools. Above all, the increase in surface hardness improves cutting performance because of it provides higher wear resistance.

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.

Edge Sharpening and Surface Modification of PcBN Cutting Tool by Pulsed Laser Grinding

2012 ◽  
Vol 523-524 ◽  
pp. 131-136 ◽  
Author(s):  
Daisuke Suzuki ◽  
Fumihiro Itoigawa ◽  
Keiich Kawata ◽  
Tetsuro Suganuma ◽  
Takashi Nakamura
Keyword(s):  
Surface Modification ◽  
High Precision ◽  
Chemical Reactivity ◽  
Cutting Tools ◽  
Pulsed Laser ◽  
Tool Material ◽  
Lateral Force ◽  
Hardened Steel ◽  
Rake Face ◽  
Diamond Grinding

PcBN cutting tools have excellent characteristics such as high degree of hardness and low chemical reactivity, so they have potential to replace high precision grinding of hardened steel with high precision cutting. PcBN might be more efficient tool material if improvement in formability, and good surface modification can be achieved. In order to solve these problems, Pulsed Laser Grinding (PLG) is applied to a shape cutting edge and to finish a rake face. After processing by the PLG, shaped cutting edges were observed with a scanning electron microscope (SEM) and measured with contact- type profilometer. As a result, cutting edges processed by the PLG are similar or shaper than that by conventional diamond grinding. In addition, as a one of effects of surface modification, The Vickers microhardness of rake faces increases by about 10 present after PLG. On the other hand, according to frictional test with lateral force microscopy, the coefficient of friction of rake face decreases by half of ordinary surface. Depending on these advantages of PLG, high precision turning of hardened steel with 58HRC in hardness by use of the tool processed by PLG can demonstrate good performance rather than a commercial tool with diamond grinding finish.

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.

scholarly journals The influence of cutting edge sharpness on surface finish in facing with round nosed cutting tools

2008 ◽  
Vol 1 (2) ◽  
pp. 70-75 ◽  
Author(s):  
T.H.C. Childs ◽  
D. Dornfeld ◽  
D.-E. Lee ◽  
S. Min ◽  
K. Sekiya ◽  
...  
Keyword(s):  
Surface Finish ◽  
Cutting Tools ◽  
Cutting Edge ◽  
Edge Sharpness

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.

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.

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.

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.

Development of New Scaife Machine for Making the High Precision Diamond Cutting Tools

2012 ◽  
Vol 523-524 ◽  
pp. 497-502 ◽  
Author(s):  
Kazuhito Nishimura ◽  
Masahiro Ooka ◽  
Hideki Sasaoka
Keyword(s):  
High Precision ◽  
Diamond Tool ◽  
Cutting Tools ◽  
Cutting Edge ◽  
Diamond Cutting ◽  
Diamond Cutting Tools ◽  
Submicron Scale ◽  
The Face ◽  
Overhang Length ◽  
Polishing Machine

We have developed a new scaife polishing machine for the purpose of polishing the high precision diamond cutting tools. As a high precision cutting tool, the high sharpness and flawless cutting edge are required. By using this polishing machine, the sharpness of a diamond tool at the cutting edge can be controlled within the range of 20nm. This machine is equipped with a submicron-scale mirror finished hardened-steel polishing Scaife, a supporting table can reduce the face deflection to less than 1μm, and a plastic diamond tool holder for protecting the edge of the diamond tool from the unexpected shock, which is supported by three points consisting of the edge of diamond tip and two control screws, this structure can help to adjust the work surface to any angles by only adjusting the two control screws. To facilitate the advanced angle operations, the algorithm was created to calculate the overhang length variations of the two control screws for controlling the changes of roll- and pitch-angle of the diamond tools.

UKP-laserbasierte Herstellung von Netzen unterschiedlicher Transmissionsgrade/USP-laser based production of meshes of different transmission degrees

2020 ◽  
Vol 110 (11-12) ◽  
pp. 787-789
Author(s):  
Marcel Simons ◽  
Till Rusche ◽  
Tobias Valentino ◽  
Tim Radel ◽  
Frank Vollertsen
Keyword(s):  
High Precision ◽  
Processing Speed ◽  
Laser Processing ◽  
Short Pulse ◽  
High Quality ◽  
Mesh Width ◽  
Variable Transmission ◽  
Ultra Short Pulse ◽  
Mesh Structures

Die Ultrakurzpuls (UKP)-laserbasierte Bearbeitung erlaubt die Herstellung von Netzstrukturen mit verschiedenen Transmissionsgraden. Vorteile der UKP-laserbasierten Herstellung der Netze liegen vor allem in der hohen Präzision und Bearbeitungsgeschwindigkeit. Die UKP-Laserbearbeitung ermöglicht die Herstellung von Netzen aus Aluminium in hoher Qualität, bezogen auf die Stegbreitenabweichung von < 8 µm, mit variablen Transmissionsgraden. Ultra-short pulse (USP) laser based processing enables the production of mesh structures with different degrees of transmission. The advantages of USP-based production of mesh structures are mainly the high precision and processing speed. USP laser processing enables the production of meshes of aluminum in high quality, with respect to the mesh width deviation of < 8 µm with variable transmission degrees.

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