Effect of feed rate, workpiece hardness and cutting edge on subsurface residual stress in the hard turning of bearing steel using chamfer+hone cutting edge geometry

Hua, Jianmin; Shivpuri, Rajiv; Cheng, Xiaomin; Bedekar, Vikram; Matsumoto, Yoichi; Hashimoto, Fukuo; Watkins, Thomas R.

doi:10.1016/j.msea.2004.11.011

Cited by 149 publications

(77 citation statements)

References 8 publications

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“…Of these experimental techniques, two have been the most widely used and accepted for machined components: X-ray diffraction technique [6,7] and the hole-drilling method [8,9]. More recently, different indentation techniques have been used to determine residual stresses in machined parts.…”

Section: Related Workmentioning

confidence: 99%

Evaluation of Residual Stresses Induced by High Speed Milling Using an Indentation Method

Díaz¹,

Mammana²,

Guidobono³

2012

MME

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In this work, a recently developed method based on the change of distance between collinear indents is used to evaluate different states of residual stress, which were generated in samples of AA 6082-T6 and AA 7075-T6 aluminium alloys milled at high speed. One of the advantages of this method, which needs a universal measuring machine, is not requiring neither the use of specific equipment nor highly skilled operators. Also, by integrating an indentation device to the mentioned machine, the absolute error of measurement can be reduced. In results obtained in samples subjected to different cutting conditions it is observed a correlation between the stress values and the depth of cut, showing the AA 6082-T6 alloy higher susceptibility to be stressed. Furthermore, the high sensitivity of the method allowed detecting very small differences in the values reached by different normal components in the zones corresponding to climb and conventional cutting. It is important to note that these differences were similar for both evaluated alloys. Finally, the directions associated with the principal components of residual stress, where maximum local plastic stretching occurs, were found to be strongly dependent on the rolling direction prior to machining.

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Section: Related Workmentioning

confidence: 99%

Evaluation of Residual Stresses Induced by High Speed Milling Using an Indentation Method

Díaz¹,

Mammana²,

Guidobono³

2012

MME

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“…When hone radius increases from 20 to 100 µm (at chamfer angle of 20º), the maximum edge temperature increases to more than 90 ºC. Therefore, using chamfer plus hone for cutting edge preparation is better from the tool wear point of view, if required residual stress level can be reached [24]. Chamfer tool helps to increase compressive residual stress but its effect is less than that of increasing the hone radius.…”

Section: Tool Edge (Curvilinear Edge/ Wiper Geometry)mentioning

confidence: 99%

Untitled

2011

JESTR

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The effect of cutting tool geometry has long been an issue in understanding mechanics of turning. Tool geometry has significant influence on chip formation, heat generation, tool wear, surface finish and surface integrity during turning. This article presents a survey on variation in tool geometry i.e. tool nose radius, rake angle, groove on the rake face, variable edge geometry, wiper geometry and curvilinear edge tools and their effect on tool wear, surface roughness and surface integrity of the machined surface. Further modeling and simulation approaches on tool geometry including one approach developed in a recent study, on variable micro-geometry tools, is discussed in brief.Keywords: Curvilinear edge, rake angle, grooved tools, nose radius, variable geometry. Stringent control on the quality of machined surface and sub-surface during turning is most important consideration a part from considering the tool life. In order to attain sufficiently high production rates at minimum cost, optimization of cutting tool geometry is necessary [1], [2]. The design of cutting edge geometry and its influence on machining performance have been a research topic in metal cutting for a long time. Edge preparation has a critical effect on the tool life. A tool with poor edge preparation may chip and fail quickly [3]. Users expect to have more and more productivity in their machining processes (high removal rate of work-material) and low wear of their cutting tools (long tool life). These demands require major improvements in the design of cutting tools: new substrates, new coatings, cutting tool geometry and materials etc. According to tool manufacturers, the manufacturing procedures of their cutting tools, especially the micro-geometry preparation (cutting edge etc.), have a major influence on their performance and on their reliability [4]. Edge preparation must be carefully selected for a given application because it affects the surface integrity of the machined workpiece (white layer, residual stresses etc.) [5]. Heat generated during hard turning is also affected by edge preparation due to change in work material flow around the cutting edge. For example, a chamfered face provides excessive negative angle to the cutting action and results in high heat generation. PCBN tools rapidly wear out during hard turning at high cutting speeds mainly due to attained temperatures [6].It is important to consider the tool-edge effect in order to better understand the chip formation mechanism and accurately predict machining performances, such as cutting forces, cutting temperatures, tool wear, surface finish and the machined surface integrity. The methods commonly employed include experimental, analytical, and numerical methods [7]. The tool geometry effects on turning performance parameters are mentioned in Figure1.It is demonstrated that the cutting tool edge geometry significantly influences many fundamental aspects such as cutting forces, chip formation, cutting temperature, tool wear, tool-life and characteristics like sur...

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“…This ferrous compound on the machined surface was related to the cutting temperature. Investigations on the cutting temperature [4,9,12] showed that temperature in the cutting area was much higher in the machining of nickel-based alloys than the conventional steels at the higher cutting parameters. The higher cutting temperature made some elements of NiCr20TiAl alloy to be oxidized into oxides.…”

Section: Surface Topographymentioning

confidence: 99%

“…Therefore, care must be taken to ensure the surface integrity of components during machining [10,11]. The cutting tool can alter the quality of the machined surface under optimum cutting conditions [1,2,[9][10][11][12]. Al 2 O 3 and TiN have lower conductivity and higher fracture toughness, respectively.…”

Section: Introductionmentioning

confidence: 99%

Study on finish-turning of NiCr20TiAl nickel-based alloy using Al2O3/TiN-coated carbide tools

Zou

Chen

2010

Int J Adv Manuf Technol

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Al 2 O 3 /TiN-coated tungsten carbide tools were used for finish-turning of NiCr20TiAl nickel-based alloy under various cutting conditions. The cutting forces, surface integrity, and tool wear were investigated, and their formation mechanisms were discussed. The inter-diffusing and transferring of elements between Al 2 O 3 /TiN-coated tungsten carbide tool and NiCr20TiAl nickel-based alloy were studied during machining. The plastic flow of NiCr20TiAl alloy was present on the machined surface by the lower cutting forces. The flaking of coating and matrix of tools and the heavier plucking and cavities of the machined surface were induced by the higher cutting forces at higher cutting parameters. The tensile residual stress was engendered on the machined surface and increased with the cutting parameters. In view of surface quality and tool wear, the cutting speed of 60 min and feed of 0.15 mm/r are recommended, and depth of cut should not exceed 0.4 mm when Al 2 O 3 /TiN-coated carbide tools are used for the finish-turning of the NiCr20TiAl alloy.

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Effect of feed rate, workpiece hardness and cutting edge on subsurface residual stress in the hard turning of bearing steel using chamfer+hone cutting edge geometry

Cited by 149 publications

References 8 publications

Evaluation of Residual Stresses Induced by High Speed Milling Using an Indentation Method

Evaluation of Residual Stresses Induced by High Speed Milling Using an Indentation Method

Untitled

Study on finish-turning of NiCr20TiAl nickel-based alloy using Al2O3/TiN-coated carbide tools

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