A review of turning of hard steels used in bearing and automotive applications

Abstract

Hard turning is a recent technology that involves machining of hard steels using modern machine tools. Hard machining presents challenges in terms of selection of tool insert with improved tool life and high-precision machining. Turning of hardened steels using single-point cutting tool has got considerable interest among manufacturers of ball bearings, automotive, gear, and die industry. Hard turning in the automotive industry and bearing applications typically has a number of potential benefits over traditional form grinding including lower equipment costs, shorter setup time, and fewer process steps which in turn provides high flexibility and ability to cut complex geometries. Moreover, the hard turning process is usually carried out without coolant/lubricant and thus, the problem of storage, handling, and disposal of cutting fluid is eliminated, and at the same time, it probably favors the health of operators. This paper presents an overview of the past research hard turning using hard turning tools such as PCBN, cubic boron nitride, Ceramics, Carbide, etc. Major hard turning cutting materials and effect of hard turning process parameters on cutting forces, heat generation during cutting, surface finish and surface integrity, and tool wear have been discussed in light of the findings of the past research.

Machinability of Stone—Plastic Materials During Diamond Planing

“…Power consumed in materials machining is mainly converted into cutting heat, which directly or indirectly causes machining problems, such as tool wear and a loss of machining precision [16]. An experimental study of diamond milling of silicon carbide was designed by Iqbal et al [17]; they found that cutting temperature decreases with an increase in cutting depth at a higher feed rate, but increases at low feed rates.…”

Analysis of tool vibration and surface roughness with tool wear progression in hard turning: An experimental and statistical approach

“…These materials are preferred for their exceptional mechanical properties like high hardness; high wear opposition. These materials are extensively used in applications like chain sprocket, steel ball bearings, transmission shaft, valve casing, engine parts, gears, bearing, dies, punches, nozzles, railways components, helicopter camshaft [1][2]. The conventional processes for turning hardened steel are electricdischarge and grinding; and are in limited is use due to high tooling cost, low surface finish and material removal rate, faster wear.…”

Experimental Investigation of Tool Wear and Induced Vibration in Turning High Hardness Aisi52100 Steel Using Cutting Parameters and Tool Acceleration

“…Turning of high hardness material with hardness range 45-70 HRC is carried out by a single point cutting tool and is referred to as hard turning. It is widely used in aviation, automotive industries for manufacturing components such as shafts, bearings, camshaft gears and landing gear, engine attachment fittings and constant velocity joints, and so on [1]. The hardened steels are favored because of their special mechanical properties like high hardness, high wear opposition etc.…”