Trail Investigation on Chip of High-Speed and Dry Cutting on Hardened Steel with PCBN Tool

2010 ◽  
Vol 142 ◽  
pp. 26-30
Author(s):  
Zhen Hua Qing ◽  
Dun Wen Zuo ◽  
Feng Xie ◽  
Chong Gao Zhang
Keyword(s):  
Alloy Steel ◽  
High Speed ◽  
Cutting Temperature ◽  
Hardened Steel ◽  
Work Piece ◽  
Dry Cutting ◽  
Pcbn Tool ◽  
Hardened Alloy ◽  
On Chip ◽  
Tool Cutting

The high-speed hard and dry cutting chips of hardened alloy-steel with PCBN tool is presented in this paper: After the work piece temperature measured by ThermaVision infrared thermometer, it is proved that the heat generated by cutting is carried out by chips; After SEM analyzed chip it is proved that the cutting temperature is increased and then fallen and the PCBN tool suitable for high-speed hard and dry cutting. It is suitable for PCBN tool cutting hardened alloy-steel 42CrMo instead of grinding.

Experiments on High-Speed and Dry Cutting with PCBN Tool

2010 ◽  
Vol 431-432 ◽  
pp. 114-117
Author(s):  
Hai Dong Yang ◽  
Zhen Hua Qing ◽  
Feng Xie ◽  
Chong Gao Zhang
Keyword(s):  
Tool Wear ◽  
Alloy Steel ◽  
High Speed ◽  
Cutting Speed ◽  
Cutting Mechanism ◽  
Dry Cutting ◽  
Pcbn Tool ◽  
Workpiece Temperature ◽  
Hardened Alloy ◽  
Cutting Speeds

This paper deals with the High-speed Hard and Dry Cutting mechanism of hardened alloy-steel with PCBN tool: the cutting speed and workpieces temperature and tool wear are being discussed in different cutting speeds when cutting alloy-steel 42CrMo. After the workpiece temperature measured by ThermaVision, it is proved that the workpiece temperature was not high and changed little. Through the SEM and EDS analyses for chip and tool wear, it is proved that PCBN tool is suitable for High-speed Hard and Dry Cutting. It is suitable for PCBN tool to cut hardened alloy-steel 42CrMo instead of grinding.

scholarly journals Cutting Performance and Wear/Damage Characteristics of PCBN Tool in Hard Milling

2019 ◽  
Vol 9 (4) ◽  
pp. 772 ◽  
Author(s):  
Haining Gao ◽  
Xianli Liu ◽  
Zhitao Chen
Keyword(s):  
High Speed ◽  
Failure Modes ◽  
Cutting Temperature ◽  
Hardened Steel ◽  
Cutting Performance ◽  
Machining Process ◽  
High Rate ◽  
Pcbn Tool ◽  
Damage Characteristics ◽  
Wear Damage

In the intermittent machining of hardened steel for the die and mold industry, determining how to reduce the wear of PCBN (Polycrystalline Cubic Boron Nitride) tools and improve their machining efficiency and quality is an important subject. This study investigated the intermittent machining of hardened steel (Cr12MoV, 59HRC (Rockwell hardness)) using uncoated PCBN tools to determine the cutting performance (cutting force, chip morphology, surface quality, tool life, cutting temperature) and the wear/damage characteristics of the tools. The results showed that the cutting performance of a PCBN tool was better than that of a cemented carbide tool. The wear mechanism on the PCBN tool flank was diffusion wear, adhesive wear, and oxidation wear. The main failure modes of the PCBN tool in the machining process of hardened steel at low speed were tool micro-chipping, the conchoidal damage of the rake face, and the larger damaged area of the flank face. The main failure modes of the PCBN tool in the machining process of hardened steel at high speed were flank wear and high-rate fatigue damage.

Effect of Corner Radius on the Vibration Amplitude in PCBN Tool Cutting Hardened Steel Process

2016 ◽  
Vol 836-837 ◽  
pp. 228-233
Author(s):  
Liang Wang ◽  
Guang Jun Chen ◽  
Ting Zhang ◽  
Ding Wen Wang ◽  
Ying Wang
Keyword(s):  
Vibration Amplitude ◽  
High Speed ◽  
Cutting Parameters ◽  
Hardened Steel ◽  
Pcbn Tool ◽  
Tool Vibration ◽  
Corner Radius ◽  
Cnc Lathe ◽  
Cutting Vibration ◽  
Tool Cutting

Abstract: Corner radius as a non-main cutting parameters, study of corner radius about cutting vibration is relatively small.Turning experiments use PCBN tool in CAK4085 CNC lathe,cutting hardened steel HRC50-52 Cr12MoV and hardened steel HRC62-64 GCr15, eddy current sensor measure the tool vibration amplitude of each group parameters, analysis influence of the corner radius for tool vibration amplitude. With corner radius increases, tool vibration amplitude increases. Research will contribute to the development of high-speed machining of hardened steel.

Research on High-Speed Cutting of Cr12MoV Hardened Steel - A Review

2020 ◽  
Vol 15 ◽  
Author(s):  
Fei Sun ◽  
Guohe Li ◽  
Qi Zhang ◽  
Meng Liu
Keyword(s):  
High Speed ◽  
Cutting Temperature ◽  
High Hardness ◽  
High Strength ◽  
Hardened Steel ◽  
Parameters Optimization ◽  
Future Research ◽  
High Speed Machining ◽  
Machined Surface ◽  
Stamping Die

: Cr12MoV hardened steel is widely used in the manufacturing of stamping die because of its high strength, high hardness, and good wear resistance. As a kind of mainstream cutting technology, high-speed machining has been applied in the machining of Cr12MoV hardened steel. Based on the review of a large number of literature, the development of high-speed machining of Cr12MoV hardened steel was summarized, including the research status of the saw-tooth chip, cutting force, cutting temperature, tool wear, machined surface quality, and parameters optimization. The problems that exist in the current research were discussed and the directions of future research were pointed out. It can promote the development of high-speed machining of Cr12MoV hardened steel.

Predicting the High Speed Cutting Process of Titanium Alloy by Finite Element Method

2011 ◽  
Author(s):  
Xiangqin Zhang ◽  
Xueping Zhang ◽  
A. K. Srivastava
Keyword(s):  
Finite Element ◽  
Cutting Forces ◽  
High Speed ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Cutting Process ◽  
Fe Model ◽  
Dry Cutting ◽  
Friction Coefficients ◽  
Machining Conditions

To predict the cutting forces and cutting temperatures accurately in high speed dry cutting Ti-6Al-4V alloy, a Finite Element (FE) model is established based on ABAQUS. The tool-chip-work friction coefficients are calculated analytically using the measured cutting forces and chip morphology parameter obtained by conducting the orthogonal (2-D) machining tests. It reveals that the friction coefficients between tool-work are 3∼7 times larger than that between tool-chip, and the friction coefficients of tool-chip-work vary with feed rates. The analysis provides a better reference for the tool-work-chip friction coefficients than that given by literature empirically regardless of machining conditions. The FE model is capable of effectively simulating the high speed dry cutting process of Ti-6Al-4V alloy based on the modified Johnson-Cook model and tool-work-chip friction coefficients obtained analytically. The FE model is further validated in terms of predicted forces and the chip morphology. The predicted cutting force, thrust force and resultant force by the FE model agree well with the experimentally measured forces. The errors in terms of the predicted average value of chip pitch and the distance between chip valley and chip peak are smaller. The FE model further predicts the cutting temperature and residual stresses during high speed dry cutting of Ti-6Al-4V alloy. The maximum tool temperatures exist along the round tool edge, and the residual stress profiles along the machined surface are hook-shaped regardless of machining conditions.

Diffusion and Oxidation Wear of PCBN Tool when Cutting Materials Difficult-to-Cut Based on Thermodynamics

2014 ◽  
Vol 538 ◽  
pp. 54-57
Author(s):  
Fang Shao ◽  
Yu Ting Wang ◽  
Li Jing Zou ◽  
Yan Ying Wu ◽  
Dong Sun
Keyword(s):  
High Temperature ◽  
High Speed ◽  
Cutting Temperature ◽  
Tool Material ◽  
Diffusion Reaction ◽  
Depth Of Cut ◽  
Pcbn Tool ◽  
Diffusion Wear ◽  
Pcbn Tools ◽  
Oxidation Wear

Cutting temperature always highly reaches over to 1000°C when high speed machining with PCBN tools. Diffusion of tool material element may have important influence on tool wear at such high temperature, the diffusion wear and oxidation wear have become the major wear mechanism. In this paper, the rules of diffusion wear and oxidation wear for PCBN cutting tools are proposed and analyzed based on thermodynamics theory. Dissolution concentrations in typical normal workpice materials of PCBN tool material at different temperature are then calculated. Diffusion reaction rules in high temperature are developed and analyzed using Gibbs free energy criterion. The machining tests were conducted using the PCBN tools at different cutting speeds of 50, 95,100 and 180 m/min, feed of 0.1, 0.2 and depth of cut of 0.1, 0.8, 1, and 1.5 mm respectively on PUMA300LM numerically-controlled lathe. It was found that the theoretical results were uniform with the experimental data; the results will provide useful references for tool material design and selection.

Chip Rebonding in Dry Turning of Nickel Based Alloys

2009 ◽  
Author(s):  
Jae-Wook Oh ◽  
Hsin-Yu Kuo ◽  
Kevin Meyer ◽  
Roger Lindle ◽  
Howard Weaver ◽  
...  
Keyword(s):  
High Speed ◽  
Cutting Speed ◽  
Taguchi Methods ◽  
Influential Factor ◽  
Metallographic Analysis ◽  
Dry Cutting ◽  
Workpiece Material ◽  
Screening Design ◽  
Machined Parts ◽  
On Chip

At some cutting conditions chips formed during high-speed face turning of nickel based alloys are re-bonded to the machined workpiece surface, even when coolant is applied. Unfortunately, chip-rebonding reduces surface quality, which leads to a shorter fatigue lives for machined parts. Although several researchers have documented this phenomenon and its effects, the root causes of this phenomenon is currently unknown. In order to determine the root causes of chip rebonding, past test samples exhibiting chip rebonding were first analyzed. Metallographic analysis revealed that the chip rebonding material is the same as the workpiece material and that the bonding is mechanically driven. Next, screening design of experiments (DOE) were completed to reliably reproduce chip rebonding in dry cutting cases. Chip rebonding detection and severity were measured using multiple equally spaced surface roughness measurements (Rt parameter). In addition, in-process cutting forces and tool wear measurements were recorded and compared. Finally Taguchi methods were applied to identify the key variables their influence on chip-rebonding. In dry cutting tests it was found that decreasing feed-rate while cutting at a constant cutting speed is the most influential factor in obtaining chip rebonding. High-speed video revealed that at lower feed-rates the chip curls back to the surface of workpiece, while at higher feed-rates the chip flows away from the cutting region with minimal curl. Additional testing performed verifies this theory.

Comparative Study on Cutting Force Simulation Using DEFORM 3D Software during High Speed Machining of Ti-6Al-4V

2020 ◽  
Vol 856 ◽  
pp. 50-56
Author(s):  
Kundan Kumar Prasad ◽  
Santosh Kumar Tamang ◽  
M. Chandrasekaran
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Temperature ◽  
Experimental Result ◽  
Depth Of Cut ◽  
Work Piece ◽  
High Speed Machining ◽  
3D Software ◽  
Deform 3D

The finite element-based machining simulations for evaluation/computation of different machining responses (i.e., cutting temperature, tool wear, cutting force, and power/energy consumption) are investigated by number of researchers. In this work, finite element machining simulation was performed to obtain knowledge about cutting forces during machining of hard materials. Titanium alloy (Ti-6Al-4V) has been increasingly used in aerospace and biomedical applications due to high toughness and good corrosion resistance. The high speed machining (HSM) simulation of Ti-6Al-4V work-piece using carbide tool coated with TiCN has been conducted with different combination of cutting conditions for prediction of main cutting force (Fz). The simulated result obtained from Deform 3D software is validated with experimental result and it was found that the result found in good agreement. The parametric variation shows that depth of cut and feed are influencing parameters on cutting force.

Study on Chip Breaking of HSS Tool with Convex Stripe

2014 ◽  
Vol 685 ◽  
pp. 90-93
Author(s):  
Zhong Liang Wu ◽  
Jie Zhao ◽  
Yan Lin Wang
Keyword(s):  
Aluminum Alloy ◽  
High Speed ◽  
Cutting Tool ◽  
Experimental Results ◽  
Manufacturing Processes ◽  
Cutting Depth ◽  
Chip Breaking ◽  
On Chip ◽  
Tool Cutting ◽  
Cutting Experiments

Chip breaking is important during manufacturing processes. A method of chip breaking is described. Common high speed tool was selected as cutting tool. The convex stripe was made by the laser instrument on the rake of cutting tool. Cutting experiments of aluminum alloy were carried out with this kind of tools. Experimental results show that chip breaking of tools with convex stripe is easier than ordinary tools. And the chip shape is always arc. The chip created by tools with convex stripe breaks more easily when cutting depth is less than 0.5mm. There is no damage on cutting tool with this method which is simple for manufacture.

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