Experimental-Analytical Method for Temperature Determination in the Cutting Zone during Orthogonal Turning of GRADE 2 Titanium Alloy

Ślusarczyk, Łukasz

doi:10.3390/ma14154328

Cited by 8 publications

(8 citation statements)

References 35 publications

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“…The results of the chip compression for the 62SiMnCr4 steel workpiece are shown in Figure 13. According to Slusarczyk [58], the tube wall thickness reduction involved two series of orthogonal turning, requiring the proper experimental studies. The first series of experiments were made for the tube wall thickness of ap = 0.5 mm.…”

Section: Resultsmentioning

confidence: 99%

The Influence of Cutting Parameters on Plastic Deformation and Chip Compression during the Turning of C45 Medium Carbon Steel and 62SiMnCr4 Tool Steel

et al. 2022

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The paper deals with the issue of cutting zone and chip compression. The aim was to analyse the microstructure transverse section of the cutting zone on a metallographic cut, due to determined values of chip compression and plastic deformation, which affect the cutting process efficiency. The tested cutting tool material was coated with cemented carbide. The selected workpiece materials were C45 medium carbon steel of ISO grade and 62SiMnCr4 tool steel of ISO (W.Nr. 1.2101) grade. In the experiments, a DMG CTX alpha 500 turning centre was used. The cutting speed and feed were varied, and the depth of the cut was kept constant during the turning. The plastic deformation and chip compression determine the efficiency of the cutting process. The higher compression requires more work to perform the process and, therefore, it requires more energy for doing so. With the increase of the cutting speed, the deformation for C45 steel is decreased. The rapid deformation reduction was observed when the cutting speed was increased from 145 m/min to 180 m/min. Generally, deformation is decreasing with the increase of the feed. Only at a cutting speed of 145 m/min was the deformation elevation observed, when the feed was increased from 0.4 mm to 0.6 mm. During the turning of the 62SiMnCr4 tool steel we observed an error value at a cutting speed of 145 m/min and a feed of 0.4 mm was the middle cutting parameter. However, feed dependence was clear: With an increase of the feed, the plastic deformation was decreasing. This decreasing was more rapid with the increasing of the cutting speed. Besides plastic deformation, there was analysed chip compression as well. With the increasing of the cutting speed, there was a decrease of the chip compression. Due to a lack of information in the area of the chip compression and the plastic deformation in the cutting process, we decided to investigate the cutting zone for the turning of tool steels 62SiMnCr4, which was compared with the reference steel C45. The results could be applied to increase the efficiency of the process and improvement of the surface integrity.

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Section: Resultsmentioning

confidence: 99%

The Influence of Cutting Parameters on Plastic Deformation and Chip Compression during the Turning of C45 Medium Carbon Steel and 62SiMnCr4 Tool Steel

et al. 2022

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“…Contact and non-contact methods are used for this purpose. They are based on phenomena of conduction and radiation, respectively [9,11]. Examples of the use of these two methods, i.e., the use of a thermocouple and a thermal imaging camera, are presented, e.g., in Grochalski et al [12].…”

Section: Introductionmentioning

confidence: 99%

“…Various models based on different assumptions and inputs, e.g., the modified chip formation model, the Komanduri-Hou model, or the Ning-Liang model, can be found in the literature [17]. By means of them, attempts are made to describe the behavior of a given material during its decohesion [11]. In case of orthogonal cutting, two main zones are distinguished: the primary shear zone (PSZ) which lies between the workpiece and the chip and the secondary shear zone (SSZ) related to the flow of the chip on the rake face of a tool [18].…”

Section: Introductionmentioning

confidence: 99%

“…In case of orthogonal cutting, two main zones are distinguished: the primary shear zone (PSZ) which lies between the workpiece and the chip and the secondary shear zone (SSZ) related to the flow of the chip on the rake face of a tool [18]. Many models described in the literature were built [3,5,8,11,[19][20][21] based on such scheme. Models of this type, most often based on the Johnson-Cook (J-C) constitutive equation and Oxley's shear theory [22,23], are based on several assumptions.…”

Section: Introductionmentioning

confidence: 99%

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Estimation of temperature in the cutting area during orthogonal turning of grade 2 titanium

Ślusarczyk

Franczyk

2023

Int J Adv Manuf Technol

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The authors introduce an experimental-analytical method for determining the average temperature values in the PSZ (primary shear zone) and the SSZ (secondary shear zone) during orthogonal turning of grade 2 titanium with a use of an uncoated carbide tool with a positive rake angle and a flat rake face. The presented method is based on an algorithm in which the values of shear stress in the PSZ and the SSZ are calculated by means of the Johnson–Cook constitutive equation and Oxley’s model of cutting mechanics. Average temperature values in the PSZ and the SSZ are determined by iteratively finding the minimum difference between the calculated stress values. As its inputs, the algorithm uses the values of the feed and the tangential cutting force components, the value of chip flow velocity on the rake face, and the constants of the Johnson–Cook constitutive equation. The model was validated with a use of empirical data collected during the experiments. The test rig consisted of a KNUTH Masterturn 400 precision lathe equipped with a dynamometer, a high-speed camera, and a thermal imaging camera.

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“…The problems of high temperatures and cutting forces in the cutting zone that adversely affect tool life and wear is very important [4][5][6]. The experimental methods for temperature and cutting force determination in the cutting zone are described in the literature [7,8]. Cutting tools materials used nowadays in different machining technologies are mainly cemented carbides-with 53% of all cutting materials used, high speed steels (20%), and ceramic, PcBN, and PCD (together 19%) [1,2].…”

Section: Introductionmentioning

confidence: 99%

Impact of Deposition of the (TiBx/TiSiyCz) x3 Multilayer on M2 HSS on the Cutting Force Components and Temperature Generated in the Machined Area during the Milling of 316L Steel

2022

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High-speed steel (HSS) tools account for 20 percent of the cutting tools materials’ global market. This is due to both their significant toughness and resistance to cracking, compared to cemented carbides. Covering steel tools with hard coatings clearly improves their mechanical properties, wear resistance, and significantly increases their durability. Physical vapor deposition methods are preferred for coating metal substrates, as they allow low temperature deposition. The most widely deposited coating materials are carbides, nitrides, and borides. They are combined with softer ones in the multilayer structure to promote increased resistance to cracking and delamination in comparison to monolayered structures. In this paper, the M2 steel end mills were coated by (TiBx/TiSiyCz) x3 multilayer by the pulsed laser deposition method. Coated and uncoated tools were tested in the cylindrical down milling of AISI 316L steel. Components of the cutting force and temperature generated in the machined area during dry milling were measured under two variants of operating conditions: V1 and V2. Tool wear mechanism was examined using scanning electron microscopy (SEM), accompanied by EDS analysis of worn areas. It was found that milling with higher speed (variant V2) is accompanied by lower cutting force components and a lower temperature generated in cutting area. The presence of the coating allowed lower cutting forces and temperature in the case of variant V1. The temperature measured during milling did not exceed 200 °C. The SEM observation of the edges of cutting tools indicated that the main mechanism of wear for both types of tools was abrasion. The built-up edge formation was observed in the case of tools tested at the V1 cutting parameters variant. It was assumed that it was the reason for higher cutting forces measured during milling according to this variant. The chemical composition of built-up edges was different for coated and uncoated tools. Tribo-chemical reactions were responsible for the reduction of the cutting force and temperature components observed during milling with a coated tool at V1 variant. Boron and titanium were the elements of the coating that enabled the tribo-oxidation reactions thanks to which friction was reduced. Our results show that this beneficial effect occurs with (TiBx/TiSiyCz) x3 coated tools, but can easily be lost with inadequately selected cutting parameters.

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Experimental-Analytical Method for Temperature Determination in the Cutting Zone during Orthogonal Turning of GRADE 2 Titanium Alloy

Cited by 8 publications

References 35 publications

The Influence of Cutting Parameters on Plastic Deformation and Chip Compression during the Turning of C45 Medium Carbon Steel and 62SiMnCr4 Tool Steel

The Influence of Cutting Parameters on Plastic Deformation and Chip Compression during the Turning of C45 Medium Carbon Steel and 62SiMnCr4 Tool Steel

Estimation of temperature in the cutting area during orthogonal turning of grade 2 titanium

Impact of Deposition of the (TiBx/TiSiyCz) x3 Multilayer on M2 HSS on the Cutting Force Components and Temperature Generated in the Machined Area during the Milling of 316L Steel

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