scholarly journals Effect of Speed, Feed and Depth of Cut on Machining Induced Residual Stresses in Aisi 1045 Steel

2019 ◽  
Vol 8 (2) ◽  
pp. 3397-3400 ◽  
Keyword(s):  
Residual Stresses ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
X Ray Diffraction ◽  
Left Behind ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Predicted Values ◽  
Future Work ◽  
1045 Steel

Residual stress that are induced during machining of components plays a significant part in the endurance and life of the component. The magnitude and nature of the residual stresses have been of interest to many researchers across the globe. The present work involves methodology to find out the influence of factors on the residual stresses. The machining parameters were varied and the residual stresses were determined using non-destructive method, namely X-ray diffraction. Using statistical methods, the influence of the machining parameters was ascertained. This paper aims at investigating the residual stresses in AISI 1045 steel, induced due to milling. AISI 1045 steel was considered as it is a widely used material and its applications are innumerable. It was observed that speed and feed have significant influence on stresses left behind after the machining is completed. Using statistical techniques a mathematical model was developed which is further used to predict the residual stresses. The error percentage of the predicted values was less than 5%. The results obtained were promising and future work involves the optimization of the machining parameters.

scholarly journals Effect of Cutting Conditions on the Residual Stresses Induced by Milling of AISI 1045 Steel

2019 ◽  
Vol 8 (2) ◽  
pp. 1462-1465 ◽  
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Diffraction Method ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Machining Processes ◽  
Machined Surface ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

The nature of residual stresses caused by machining processes has been relevant to the study of component performance for decades. The concept that cutting parameters affect the magnitude and nature of residual stress is well known. In order to reduce the residual stresses on a machined surface, it is important to identify the extent of the effect of cutting conditions. This paper presents the effect of depth of cut and tool speed on milling induced residual stresses. Speed and depth of cut were varied when milling several AISI 1045 Steel specimens. Stresses were measured with the X-ray diffraction method and corroborated with mathematical modelling on an FEA software. A relationship between tool speed and residual stress, and depth of cut and residual stress was thus obtained.

Predictive Modeling of Turning Operations Using Response Surface Methodology

2013 ◽  
Vol 307 ◽  
pp. 170-173 ◽  
Author(s):  
Girish Kant ◽  
Vaibhav Rao V ◽  
Kuldip Singh Sangwan
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Cutting Tool ◽  
Machining Parameters ◽  
Turning Operations ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Predicted Values ◽  
Cutting Tool Insert ◽  
1045 Steel

This paper focuses on the development of a predictive model using the measured forces acting on the cutting tool during turning operation of AISI 1045 Steel using a Tungsten Carbide cutting tool insert. On the basis of the experimental results, second order mathematical model is developed in terms of machining parameters by using the Response Surface Methodology (RSM). The results are analyzed statistically and graphically. It has been observed that the predicted values using RSM also follow the same trend as given by the measured values.

scholarly journals Evaluation of the characteristics of an AISI 1045 steel quenched in different concentration of polymer solutions of polyvinylpyrrolidone

2021 ◽  
Vol 11 (1) ◽  
Author(s):  
Eduardo da Rosa Vieira ◽  
Luciano Volcanoglo Biehl ◽  
Jorge Luis Braz Medeiros ◽  
Vagner Machado Costa ◽  
Rodrigo Jorge Macedo
Keyword(s):  
Microstructural Characterization ◽  
Exchange Capacity ◽  
X Ray Diffraction ◽  
Thermal Exchange ◽  
The Core ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Quench Hardening ◽  
Polymeric Solutions ◽  
1045 Steel

AbstractQuench hardening aims at the microstructural transformation of steels in order to improve hardness and mechanical strength. The aim phase is, in most cases, the martensite. It is necessary to heat the material until it obtains its austenitization and quenching by immersion in a fluid. Currently, it is common to use watery polymeric solutions in this procedure. These fluids, which are the mixture of polymers in water, vary their thermal exchange capacity depending on the concentrations applied. The increase in concentration minimizes the removal of heat from the part, reducing the formation capacity of martensite, and developing a lower hardness and strong steel. In this work, microstructural characteristics and properties of AISI 1045 steel quenched in solutions based on polyvinylpyrrolidone (PVP) in 10, 15, 20, and 25% concentration were evaluated. The microstructural characterization quantified the percentage of the phases in each concentration, demonstrating a reduction of martensite as the concentrations were high. The investigation of the samples by x-ray diffraction confirmed the absence of austenite retained in the material. Furthermore, a microhardness scale between the core and the surface was constructed, in which a reduction gradient of the indices of this property towards the core of the sample was evidenced.

High Speed Machining of Hardened AISI 1045 Steel

2016 ◽  
Vol 861 ◽  
pp. 63-68 ◽  
Author(s):  
Xue Ping Zhang ◽  
Shu Biao Wu ◽  
Zhen Qiang Yao ◽  
Li Feng Xi
Keyword(s):  
High Speed ◽  
Shear Bands ◽  
Chip Morphology ◽  
Machining Parameters ◽  
Chip Breaker ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
High Feed ◽  
Serrated Chips ◽  
1045 Steel

Hardened AISI 1045 steel implemented in machine tool spindle was previously ground using grinding operation. This research aims to address the feasibility of hard turning AISI 1045 using PCBN tool with chip breaker under dry condition. Chip morphology, cutting force and temperature were measured, analyzed and correlated with machining parameters. Experimental results demonstrate that serrated chips are generated at high speeds, high feed rate is an assistant to promote serrated chips, and chip breaker can help break chip into acceptable lengths. Cutting forces were characterized with periodic fluctuation along three directions as chips are serrated. Temperature at machined zone can reach as high as 1200°C, which indicates that adiabatic shear bands can be successfully achieved during the machining of hardened AISI 1045 steel without applying lubricants.

scholarly journals Selection of Machining Parameters Using a Correlative Study of Cutting Tool Wear in High-Speed Turning of AISI 1045 Steel

2018 ◽  
Vol 2 (4) ◽  
pp. 66 ◽  
Author(s):  
Luis Hernández González ◽  
Yassmin Seid Ahmed ◽  
Roberto Pérez Rodríguez ◽  
Patricia Zambrano Robledo ◽  
Martha Guerrero Mata
Keyword(s):  
High Speed ◽  
Manufacturing Industry ◽  
Cutting Tool ◽  
Flank Wear ◽  
Machining Parameters ◽  
High Speed Turning ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Coated Carbide

The manufacturing industry aims to produce many high quality products efficiently at low cost, thereby motivating companies to use advanced manufacturing technologies. The use of high-speed machining is increasingly widespread; however, it lacks a deep-rooted knowledge base needed to facilitate implementation. In this paper, response surface methodology (RSM) has been applied to determine the optimum cutting conditions leading to minimum flank wear in high-speed dry turning on AISI 1045 steel. The mathematical models in terms of machining parameters were developed for flank wear prediction using RSM on the basis of experimental results. The high speed turning experiments were carried out with two coated carbide and a cermet inserts using AISI 1045 steel as work material at different cutting speeds and machining times. The models selected for optimization were validated through the Pareto principle. Results showed the GC4215 insert to be the most optimal option, because it did not reach the cutting tool life limit and could be used for the whole range of cutting parameters selected. To quantitatively evaluate the usefulness of the cutting tools, it was proposed the coefficient of use of the tools from the results of the contour graphs. The GC4215 insert showed 100% effectiveness, followed by the GC4225 with 98.4%, and finally, the CT5015 insert with 83%.

Characterization and Performance of Monolayer Brazed Polycrystalline CBN Abrasive Tools

2010 ◽  
Vol 126-128 ◽  
pp. 621-626 ◽  
Author(s):  
Wen Feng Ding ◽  
Jiu Hua Xu ◽  
Z.Z. Chen ◽  
Hong Hua Su ◽  
Yu Can Fu ◽  
...  
Keyword(s):  
Heating Temperature ◽  
Removal Rate ◽  
Optical Microscope ◽  
Steel Matrix ◽  
X Ray Diffraction ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Abrasive Tools ◽  
And Performance ◽  
1045 Steel

Brazing experiments of polycrystalline CBN abrasive grains and AISI 1045 steel matrix using 95(72Ag-28Cu)-5Ti (wt.%) filler alloy were carried out at the heating temperature of 900 °C for the dwell time of 8 min. The microstructure of the brazing interface among PCBN grain, Ag-Cu-Ti alloy and steel matrix, was characterized with optical microscope, scanning electron microscope and X-ray diffraction equipment. Grinding performance of the brazed polycrystalline CBN abrasive tools was evaluated experimentally by comparison with monocrystalline CBN counterparts. The results show that the reaction layer between polycrystalline CBN abrasive grain and Ag-Cu-Ti filler layer consists of the compounds of Ti-nitride, Ti-borides and Ti3AlN. The resultants have played an important role in terms of strong chemical joining at the grain-filler interface. The brazed abrasive tools with polycrystalline CBN grains have given higher material removal rate and longer service life than that with monocrystalline CBN ones.

FEM Simulation of Machining AISI 1045 Steel Using Driven Rotary Tool

2015 ◽  
Vol 758 ◽  
pp. 77-82 ◽  
Author(s):  
Yanuar Burhannudin ◽  
Suryadiwansa Harun ◽  
Gusri Akhyar Ibrahim
Keyword(s):  
Feed Rate ◽  
Fem Simulation ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Work Piece ◽  
Rotary Tool ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Simulation Results ◽  
1045 Steel

This study investigates the influences of driven rotary tool (DRT) on temperatures and forces when turning AISI 1045 steel. A set of cutting conditions was used in FE simulations to predict cutting force, stresses and temperatures developed at around the edge of tool. The material cutting speed ranges were set between 20 and 250 m min-1. The rotary tool speed were 0 and 100 rpm.. The feed rate and the depth of cut were set constant. Simulation results provided the predicted cutting distribution of temperatures and stresses at the chip and work piece.

scholarly journals Influence of Heat Treatment on Residual Stress in Cold-Forged Parts

2014 ◽  
Vol 2014 ◽  
pp. 1-6 ◽  
Author(s):  
Frederico Ozanan Neves ◽  
Thiago Luis Lara Oliviera ◽  
Durval Uchoas Braga ◽  
Alex Sander Chaves da Silva
Keyword(s):  
Heat Treatment ◽  
Residual Stresses ◽  
The Body ◽  
Thermal Treatments ◽  
Cold Forming ◽  
Heat Treated ◽  
Forged Parts ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

Residual stresses are those stresses that remain in a body when there is no external load applied. Numerous factors can induce residual stresses in the material, including cold forming. Thermal treatments of steel are widely used because they can improve the mechanical properties of the steel, such as toughness, tenacity, and resistance; however, thermal treatments can also produce residual stresses. This study aims to analyze the residual stresses present in a cold-forged part after heat treatments. Half-cylinder samples of AISI 1045 steel were cold-forged, and a wedge tool was pressed into their surface, causing a strain gradient. The samples were then heat-treated by annealing, normalizing, quenching, or quenching and tempering. A numerical simulation was also performed to aid in choosing the measurement points in the samples. The results show that residual stresses are dependent on the heat treatment and on the intensity and nature of previous residual stresses in the body.

Reducing Tool Wear in CNC End Milling Operation Using Progressive Feed Rate

2014 ◽  
Vol 592-594 ◽  
pp. 716-723
Author(s):  
K.S. Badrinathan ◽  
L. Karunamoorthy
Keyword(s):  
Tool Wear ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Milling Operation ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Cnc End Milling

This study focuses on the effect of cutting parameters on the tool wear in a CNC end milling operation. Major factors which influence the tool wear are spindle speed, feed rate and depth of cut. Conventionally constant feed rate is used. In this work a concept of progressive feed rate is introduced. AISI 1045 steel has been chosen as it is widely used in manufacturing. Design of Experiments (DOE) technique was adopted to conduct the experiments. Experiments were conducted for both the existing and the proposed feed rate method and the tool wear was compared. A statistical model was developed using Design Expert software. The predicted values were compared with the experimental values and were found to be in close agreement. The model adequacy was checked using ANOVA technique.

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