Advances in the surface defect machining (SDM) of hard steels

A variety of cutting tool materials are used for the contact mode mechanical machining of components under extreme conditions of stress, temperature and/or corrosion, including operations such as drilling, milling turning and so on. These demanding conditions impose a seriously high strain rate (an order of magnitude higher than forming), and this limits the useful life of cutting tools, especially single-point cutting tools. Tungsten carbide is the most popularly used cutting tool material, and unfortunately its main ingredients of W and Co are at high risk in terms of material supply and are listed among critical raw materials (CRMs) for EU, for which sustainable use should be addressed. This paper highlights the evolution and the trend of use of CRMs) in cutting tools for mechanical machining through a timely review. The focus of this review and its motivation was driven by the four following themes: (i) the discussion of newly emerging hybrid machining processes offering performance enhancements and longevity in terms of tool life (laser and cryogenic incorporation); (ii) the development and synthesis of new CRM substitutes to minimise the use of tungsten; (iii) the improvement of the recycling of worn tools; and (iv) the accelerated use of modelling and simulation to design long-lasting tools in the Industry-4.0 framework, circular economy and cyber secure manufacturing. It may be noted that the scope of this paper is not to represent a completely exhaustive document concerning cutting tools for mechanical processing, but to raise awareness and pave the way for innovative thinking on the use of critical materials in mechanical processing tools with the aim of developing smart, timely control strategies and mitigation measures to suppress the use of CRMs.

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“…Pre-drilled laser holes in the workpiece reduce the shear strength, which is evident by observing a lower shear plane angle [90][91][92]…”

Section: Surface Defect Machiningmentioning

confidence: 99%

The Critical Raw Materials in Cutting Tools for Machining Applications: A Review

et al. 2020

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“…Energy efficient and microstructure improvement oriented sequential micro-machining processes i.e. SDM [23][24][25] and single point diamond turning (SPDT)/laser recovery [26], respectively, are also proposed in this paper. However, it may be noted that up until now SDM and SPDT/laser recovery have been performed on different machine tools.…”

Section: Accepted Manuscript 2 Definition and Classimentioning

confidence: 99%

“…Hence, they are also introduced and characterized in this paper. Basically, SDM [23][24][25] and pulse laser pre-treatment [27] are among energy efficient machining processes utilising laser ablation/turning to reduce the energy consumption as well as to improve the quality of…”

Section: Accepted Manuscript 2 Definition and Classimentioning

confidence: 99%

“…In this category of machining processes, surface defects at depths less than the uncut chip thickness are generated on top of the workpiece surface by mechanical means /laser ablation prior to carrying out the routine cutting process. It has been shown that this sequence of operation results in reduction of specific cutting energy more than the energy consumed in manufacturing the surface defects [5,[23][24][25]27] by the means of laser. This promising machining technique have been so far conducted for macro-machining on separate machine tools.…”

Section: Energy Efficient Sequential Micro-machiningmentioning

confidence: 99%

“…Using a traditional turret lathe and a CBN tool, the machined surface roughness R a on an AISI 4340 workpiece was reduced from 47 nm to 30 nm using this sequential micromachining method [23]. It may be noted that originally SDM [24] was not performed for micro-machining on a single machine tool, however, there is a great potential to integrate a laser source and micro-turning machine on a single machine tool, similar to the approach of a pulse laser pre-treated machining process [27].…”

Section: Accepted Manuscriptmentioning

confidence: 99%

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Current trends and future of sequential micro-machining processes on a single machine tool

2017

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This is a PDF file of an unedited manuscript that has been accepted for publication. As a service to our customers we are providing this early version of the manuscript. The manuscript will undergo copyediting, typesetting, and review of the resulting proof before it is published in its final form. Please note that during the production process errors may be discovered which could affect the content, and all legal disclaimers that apply to the journal pertain.

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An in-depth analysis of tool wear mechanisms and surface integrity during high-speed hard turning of AISI D2 steel via novel inserts

Khan

Ameer

Uddin

et al. 2022

Int J Adv Manuf Technol

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Over the years, machinists have been exploring the hard part turning of AISI D2 steels. Initially, cylindrical grinding was used for this purpose, but it was later replaced by single-point turning due to its advantages such as high material removal, low cost, and greater flexibility. Conventional inserts are used in single-point turning, but they have been reported to have large radial forces, high notch wear, and poor surface finish. Therefore, multi-radii wiper inserts were designed to overcome these machining issues, but their use was restricted to shallower depths of cut and moderate feed rates because of the thick chips produced by the high entry angle. Prime inserts, on the other hand, were designed with a modest entry angle, making them ideal for evaluating tool wear/life, material removal and surface roughness at greater cutting speeds, depths of cut, and feed rates. It was observed that cutting speed has a significant effect on tool wear/life with a contribution of 55.38% followed by feed rate (13.72%) and depth of cut (11.43%). Cutting speed (84.87%) and feed rate (13.01%) are observed to be the most significant parameters controlling material removed. It was also observed that feed rate has a significant effect on workpiece surface roughness with a contribution of 67.30% followed by depth of cut (20.60%), whereas cutting speed had no significant effect on surface roughness. Moreover, it is found that prime insert outperformed wiper and conventional inserts in terms of tool life/wear and surface roughness.

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Advances in the surface defect machining (SDM) of hard steels

Cited by 18 publications

References 43 publications

The Critical Raw Materials in Cutting Tools for Machining Applications: A Review

The Critical Raw Materials in Cutting Tools for Machining Applications: A Review

Current trends and future of sequential micro-machining processes on a single machine tool

An in-depth analysis of tool wear mechanisms and surface integrity during high-speed hard turning of AISI D2 steel via novel inserts

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