Hard turning of high-carbon high chromium tool steel using CBN tools under different lubricating/cooling conditions (original) (raw)
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Journal of Mechanical Science and Technology, 2012
The main of the present study is to investigate the effects of process parameters (cutting speed, feed rate and depth of cut) on performance characteristics (tool life, surface roughness and cutting forces) in finish hard turning of AISI 52100 bearing steel with CBN tool. The cutting forces and surface roughness are measured at the end of useful tool life. The combined effects of the process parameters on performance characteristics are investigated using ANOVA. The composite desirability optimization technique associated with the RSM quadratic models is used as multi-objective optimization approach. The results show that feed rate and cutting speed strongly influence surface roughness and tool life. However, the depth of cut exhibits maximum influence on cutting forces. The proposed experimental and statistical approaches bring reliable methodologies to model, to optimize and to improve the hard turning process. They can be extended efficiently to study other machining processes.
Journal of Mechanical Science and Technology, 2011
The present study, aims to investigate, under turning conditions of hardened AISI H11 (X38CrMoV5-1), the effects of cutting parameters on flank wear (VB) and surface roughness (Ra) using CBN tool. The machining experiments are conducted based on the response surface methodology (RSM). Combined effects of three cutting parameters, namely cutting speed, feed rate and cutting time on the two performance outputs (i.e. VB and Ra), are explored employing the analysis of variance (ANOVA). Optimal cutting conditions for each performance level are established and the relationship between the variables and the technological parameters is determined using a quadratic regression model. The results show that the flank wear is influenced principally by the cutting time and in the second level by the cutting speed. Also, it is that indicated that the feed rate is the dominant factor affecting workpiece surface roughness.
The International Journal of Advanced Manufacturing Technology, 2019
The main objective of this work is to evaluate the tool life and the workpiece surface roughness when applying a vegetable-based cutting fluid by minimum quantity of lubricant (MQL) at three different directions (main tool flank face, secondary tool flank face, and overhead) in turning AISI D6 hardened steel with polycrystalline cubic boron nitride (PCBN) tools with Al 2 O 3 ceramic binder and TiN coating. Dry cutting was also tested for comparisons. Tool wear analyses were performed on the tools at the end of their lives within a scanning electron microscope (SEM). The application of the cutting fluid by MQL technique in the direction between the main tool flank face and the workpiece showed better results than the dry condition. The application of MQL through other directions (overhead and between the secondary tool flank face and the workpiece) also showed competitive results. Abrasion and adhesion were the prevailing mechanisms for the wear of the tools.
2014
The current experimental study is to investigate the effects of process parameters (cutting speed, feed rate and depth of cut) on performance characteristics (surface roughness, machining force and flank wear) in hard turning of AISI 4340 steel with multilayer CVD (TiN/TiCN/Al2O3) coated carbide insert. Combined effects of cutting parameter (v, f, d) on performance outputs (Ra, Fm and VB) are explored employing the analysis of variance (ANOVA). An L9 Taguchi standard design of experiments procedure was used to develop the regression models for machining responses, within the range of parameters selected. Results show that, feed rate has statistical significance on surface roughness and the machining force is influenced principally by the feed rate and depth of cut whereas , cutting speed is the most significant factor for flank wear followed by cutting speed. The desirability function approach has been used for multi-response optimization. Based on the surface roughness, machining f...
Materials
In this study, a comparison of measured cutting parameters is discussed while machining AISI 52100 low-alloy hardened steel under two different sustainable cutting environments, those in which a dry and minimum quantity lubrication (MQL) medium are used. A two-level full factorial design method has been utilized to specify the effect of different experimental inputs on the turning trials. Experiments were carried out to investigate the effects of three basic defining parameters of turning operation which are namely cutting speed, cutting depth, feed rate effects and also the effects of the cutting environment. The trials were repeated for the combination of different cutting input parameters. The scanning electron microscopy imaging method was used to characterize the tool wear phenomenon. The macro-morphology of chips was analyzed to define the influence of cutting conditions. The optimum cutting condition for high-strength AISI 52100 bearing steel was obtained using the MQL medium...
gazi university journal of science, 2010
In all machining processes, tool wear is a natural phenomenon and it leads to tool failure. The growing demands for high productivity of machining need use of high cutting velocity and feed rate. Such machining inherently produces high cutting temperature, which not only reduces tool life but also impairs the product quality. Metal cutting fluids changes the performance of machining operations because of their lubrication, cooling, and chip flushing functions but the use of cutting fluid has become more problematic in terms of both employee health and environmental pollution. The use of cutting fluid generally causes economy of tools and it becomes easier to keep tight tolerances and to maintain workpiece surface properties without damages. Due to these problems, some alternatives has been sought to minimize or even avoid the use of cutting fluid in machining operations. Some of these alternatives are dry machining and machining with minimum quantity lubrication (MQL). This paper deals with the experimental investigation on the role of MQL on cutting temperature, tool wear, surface roughness and dimensional deviation in turning of AISI-4340 steel at industrial speed-feed combinations by uncoated carbide insert. The encouraging results include significant reduction in tool wear rate, dimensional inaccuracy and surface roughness by MQL mainly through reduction in the cutting zone temperature and favorable change in the chip-tool and work-tool interaction.
Journal of Manufacturing and Materials Processing
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 re...
International Journal of Advanced Manufacturing Technology, 2010
High-pressure coolant (HPC) delivery is an emerging technology that delivers a high-pressure fluid to the tool and workpiece in machining processes. High fluid pressure allows for better penetration of the fluid into the cutting zone, enhancing the cooling effect, and decreasing tool wear through lubrication of the contact areas. The main objective of this work is to understand how tool wear mechanisms are influenced by fluid pressure under different cutting speeds in the finish turning of AISI 1045 steel using coated carbide tools. The main finding was that the use of a lower cutting speed (v c = 490 m/min) in dry cutting resulted in tool life close to that obtained with cutting fluid, but when the cutting speed was increased (v c = 570 m/min), the high-pressure coolant was effective in prolonging the life of the cutting tool. It was also concluded that, regardless of the cutting speed and cooling/lubrication system, the wear mechanisms were the same, namely abrasion and attrition.
Journal of Physics: Conference Series, 2019
In the present work, the effects of machining factors and cutting fluid flow conditions on tool wear and surface roughness were studied. Response surface methodology technique with Face centered composite design was employed to minimize the number of experiments. The experiments were performed on a hardened AISI D2 rod using mixed ceramic (Al 2 O 3 /TiC) inserts in turning process. The effect of machining time was found to be the most influential parameter affecting tool wear, followed by cutting speed. However, machining time followed by feed rate were the most significant parameters on surface roughness. Moreover, cutting fluid condition showed substantial contribution towards decreasing tool wear rate and increasing surface finish.