Effect of edge hone radius on chip formation and its microstructural characterization in hard milling of AISI H13 steel

Li, Binxun; Zhang, Song; Yan, Zhenguo; Zhang, Jing

doi:10.1007/s00170-018-1933-x

Cited by 12 publications

(5 citation statements)

References 26 publications

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“…One option is milling the dies. Here, parameters such as type of tool and its geometry [ 5 , 6 , 7 , 8 ], the machining strategy [ 9 , 10 ] and the operational conditions [ 11 , 12 ] play an essential role on its final surface properties, and these parameters are tightly related to the service efficiency of the die (for example, fatigue resistance). Another option is the Electrical Discharge Machining (EDM) of the dies [ 13 ].…”

Section: Introductionmentioning

confidence: 99%

Surface Damaging of Brass and Steel Pins when Sliding over Nitrided Samples Cut by Finishing and Roughing EDM Conditions

et al. 2020

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In the forging industry, surface quality and surface treatments of dies are crucial parameters to extend their life. These components are usually machined by milling or by Electrical Discharge Machining (EDM), and the final surface roughness depends on the machining techniques and operational conditions used in its fabrication. After milling, a nitriding treatment is widely applied to extend its service life. Nevertheless, no scientific report that informs about nitriding after EDM has been found. Accordingly, this work focuses on the wear and friction behavior of pins made of brass and medium carbon steel sliding over AISI H13 discs, made by wire EDM in the conditions of finishing and roughing. The discs are plasma nitride, and their effect on the wear during pin-on-disc tests is evaluated. In this sense, the analysis of the surface damage for the different pins will help us to understand the service life and wear evolution of the forging dies. The results show that plasma nitride reduces the friction and prevents the degradation of the pin, independently of the material of the pin, when sliding over finishing and roughing EDM conditions.

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Section: Introductionmentioning

confidence: 99%

Surface Damaging of Brass and Steel Pins when Sliding over Nitrided Samples Cut by Finishing and Roughing EDM Conditions

et al. 2020

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“…The authors found that when edge radius increases, cutting forces, plastic deformation and compressive residual stress increase whereas the surface roughness decreases to a certain limiting value. Another study by Li et al [12], investigating the hard milling of AISI H13 steel explored the effect of edge hone radius on the chip formation mechanisms. The results showed that when the edge hone radius increases, the chip segmentation intensity and frequency increases, leading to high cutting force fluctuations.…”

Section: Introductionmentioning

confidence: 99%

Machinability Study of Hardened 1045 Steel When Milling with Ceramic Cutting Inserts

et al. 2019

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Intermittent machining using ceramic tools such as hard milling is a challenging task due to the severe mechanical shock that the inserts undergo during machining and the brittleness of ceramic inserts. This study investigates the machinability of hardened steel AISI 1045 during face milling using SiAlON and whisker (SiCW) based ceramic inserts. The main focus seeks to identify the effects of cutting parameters, milling configuration, edge preparation and work material hardness on machinability indicators such as resultant cutting force, power consumption and flank tool wear. The effects of these varying cutting conditions on performance characteristics were investigated using a Taguchi orthogonal array design L32 (21 44) and evaluated using ANOVA. Results indicate lower resultant cutting forces were recorded with honed edge inserts of SiAlON ceramic grade. In addition, a decrease in resultant cutting forces was associated with reduced feed rates and increased hardness. The feed rate and cutting speed were also identified as the greatest influencing factors in the amount of cutting power. The main wear mechanisms responsible for flank wear on the ceramic inserts are micro-scale abrasion and micro-chipping. Increased flank wear was observed at low cutting speed and high feed rates, while micro-chipping mostly ensued from the cyclic loading of the radial tool edge form, which is more susceptible to impact fragmentation. Thus, the use of tools with chamfered tool-edge preparation greatly improved observed wear values. Additional confirmation tests were also conducted to validate the results of the tests.

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“…Analysis of variance (ANOVA) for dimensional deviation is shown in table 3 for R410a coolant fluid. According to confidence level %95, the value P for each parameter that is less than 0.05 indicates that the parameter under consideration is statistically significant and effective in the process [51,52]. The P value of the model (except Feed rate) is less than 0.05, which indicates a good fit of the model with experimental results (zero values in tables mean P less than 0.0001).…”

Section: Data Analysis For Dimensional Deviationmentioning

confidence: 99%

“…Despite numerous studies on machining steels, particularly AISI 1045 steel [51][52][53][54][55][56][57][58][59][60][61][62][63][64][65], to the best of the authors' knowledge, the use of cryogenic coolant R410A and its comparison with water-soluble cutting oil (WSCO) fluid have not been observed in any study. The process variables included cutting speed (four levels), cutting depth (three levels), and feed rate (three levels), and the measurement parameters were extensively and precisely conducted in three categories: tool wear, dimensional deviation, and surface roughness.…”

Section: Introductionmentioning

confidence: 99%

Effect of R410a coolant on tool wear, dimensional deviation and surface roughness in turning of AISI 1045 steel

Khalaj,

Haghparast,

Salari

et al. 2024

Eng. Res. Express

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Friction between the tool and the workpiece during machining operations always increases the tool wear rate. Removing this problem by using fluids and cooling the tools is essential. In this research, the effects of two cooling conditions: Water Soluble Cutting Oil (WSCO) fluid and R410a coolant, on the tool wear rate, dimensional deviation and surface roughness of AISI 1045 steel (CK45) in turning with a high-speed steel (HSS) tool were investigated. The selected parameters were cutting speeds of 15, 25, 40 and 55 m/min, cutting depths of 0.5, 1 and 1.5 mm and feed rates of 0.05, 0.12 and 0.2 mm/rev. The results show that cooling by R410a coolant reduces the tool wear rate due to its high cooling power and better temperature control at the cutting zone compared to WSCO fluid. Based on the minimums of tool wear, dimensional deviation and surface roughness in different conditions, using R410a coolant can increase the cutting speed by 60% from 25 to 40 m/min. Also, in the optimal condition at a cutting speed of 40 m/min, cutting depth of 1 mm and feed rate of 0.05 mm/rev., tool wear, dimensional deviation and surface roughness are reduced by up to 20, 6 and 10 times respectively. In the optimal condition, the dimensional deviation based on the diameter difference along 300 mm is reduced to 14 µm and also the tool wear rate and surface roughness after 60 min. of turning are reduced to 20 and 3.1 µm respectively. The effect of each input variable on tool wear, dimensional deviation and surface roughness was calculated by statistical analysis and was validated by ANOVA.

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Effect of edge hone radius on chip formation and its microstructural characterization in hard milling of AISI H13 steel

Cited by 12 publications

References 26 publications

Surface Damaging of Brass and Steel Pins when Sliding over Nitrided Samples Cut by Finishing and Roughing EDM Conditions

Surface Damaging of Brass and Steel Pins when Sliding over Nitrided Samples Cut by Finishing and Roughing EDM Conditions

Machinability Study of Hardened 1045 Steel When Milling with Ceramic Cutting Inserts

Effect of R410a coolant on tool wear, dimensional deviation and surface roughness in turning of AISI 1045 steel

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