Effect of tool nose radius and tool wear on residual stress distribution in hard turning of bearing steel

Liu, Meng; Takagi, Jun-ichiro; Tsukuda, Akira

doi:10.1016/j.jmatprotec.2004.02.038

Cited by 146 publications

(72 citation statements)

References 29 publications

Supporting

Mentioning

Contrasting

Unclassified

Order By: Relevance

“…Liu and Barash [5] observed significant influence of tool geometry in residual stresses induced by orthogonal cutting of low carbon steel. Similar trend was observed by Liu et al [6] in the case of hard turning of bearing steel. Enhanced level of tensile residual stress at the machined surface due to the rounded cutting edge was observed by Thiele et al [7] when machining AISI 52100 and Arunachalam et al [8] in the case of Ni alloy Inconel 718.…”

Section: Introductionsupporting

confidence: 89%

Numerical analysis of the tool wear effect in the machining induced residual stresses

Muñoz-Sánchez

Canteli

Cantero

et al. 2011

Simulation Modelling Practice and Theory

View full text Add to dashboard Cite

Machining is a dynamic process involving coupled phenomena: high strain and strain rate and high temperature. Prediction of machining induced residual stresses is an interesting objective at the manufacturing processes modelling field. Tool wear results in a change of tool geometry affecting thermo-mechanical phenomena and thus has a significant effect on residual stresses. The experimental study of the tool wear influence in residual stresses is difficult due to the need of controlling wear evolution during cutting. Also the involved phenomena make the analysis extremely difficult. On the other hand, Finite Element Analysis (FEA) is a powerful tool used to simulate cutting processes, allowing the analysis of different parameters influent on machining induced residual stresses.The aim of this work is to develop and to validate a numerical model to analyse the tool wear effect in machining induced residual stresses. Main advantages of the model presented in this work are, reduced mesh distortion, the possibility to simulate long length machined surface and time-efficiency. The model was validated with experimental tests carried out with controlled worn geometry generated by electro-discharge machining (EDM). The model was applied to predict machining induced residual stresses in AISI 316 L and reasonable agreement with experimental results were found.

show abstract

Section: Introductionsupporting

confidence: 89%

Numerical analysis of the tool wear effect in the machining induced residual stresses

Muñoz-Sánchez

Canteli

Cantero

et al. 2011

Simulation Modelling Practice and Theory

View full text Add to dashboard Cite

show abstract

“…With the nose radius of 0.8 mm, the residual stress at the machined surface was a residual compressive stress, but the magnitude of these residual compressive stresses is small in comparison to the nose radius of 0.4 mm. Further it can be inferred that the stress pattern on the machined surface shifts from compressive stress to tensile stress as the nose radius increases in the cutting condition of this study [44].…”

Section: Dograv S Sharma J Dureja / Journal Of Engineering Scmentioning

confidence: 61%

“…There exists a tendency that the residual stresses induced at the machined surface shift from compressive stress to tensile stress as the nose radius increases in the cutting condition of this study. The effect of the nose radius on the residual stress distribution decreases greatly with the increase of the tool wear [40]. Tool nose radius effects on finish turning of hardened AISI 52100 steel was investigated.…”

Section: Dograv S Sharma J Dureja / Journal Of Engineering Scmentioning

confidence: 99%

Untitled

2011

JESTR

View full text Add to dashboard Cite

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...

show abstract

“…The produced chip was continuous in all cases. The measurements of residual stress were conducted with an X-ray diffraction technique, and the measurement conditions used in this study are listed in Table 4 [20]. The measurements of residual stress were performed by using a 'sinϕ' method.…”

Section: Experimental Workmentioning

confidence: 99%

Investigations on the Effects of Different Tool Edge Geometries in the Finite Element Simulation of Machining

Wan¹,

Wang²,

Gao³

2015

SV-JME

View full text Add to dashboard Cite

show abstract

Effect of tool nose radius and tool wear on residual stress distribution in hard turning of bearing steel

Cited by 146 publications

References 29 publications

Numerical analysis of the tool wear effect in the machining induced residual stresses

Numerical analysis of the tool wear effect in the machining induced residual stresses

Untitled

Investigations on the Effects of Different Tool Edge Geometries in the Finite Element Simulation of Machining

Contact Info

Product

Resources

About