Improvement of tool utilization when hard turning with cBN tools at varying process parameters

Gutnichenko, Оleksandr; Nilsson, Magnus; Lindvall, Rebecka; Bushlya, Volodymyr; Andersson, Mats

doi:10.1016/j.wear.2021.203900

Cited by 13 publications

(4 citation statements)

References 12 publications

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“…However, there was minimal adhesion material on the flank face with hardly any tool wear. The observed tool wear characterizations are consistent with the literature [19].…”

Section: The Tool Wearsupporting

confidence: 91%

“…They analyzed the effect of machining parameters on cutting temperature, cutting force, and surface roughness, and they found that crater wear, micro chipping, and cutting edge breakage were the main tool wear mechanisms during continuous turning [18]. Gutnichenko et al investigated the hard turning of helical gear hubs made of low-carbon alloyed steel after heat treatment with hardened up to HRC 60-63 using PCBN cutting tools; it was found that the main tool wear characterizations were flank wear and crater formation, and different strategies were also proposed to monitor tool wear and predict tool life [19]. Schultheiss et al evaluated the tool wear mechanisms in the machining of gray cast iron with PCBN tools, the results showed that flank and notch wear were the main wear mechanisms, and the non-chamfered tools exhibited the higher notch wear [20].…”

Section: Introductionmentioning

confidence: 99%

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Experimental Investigation on the Machinability of PCBN Chamfered Tool in Dry Turning of Gray Cast Iron

Yin

Shen

et al. 2022

Processes

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Polycrystalline cubic boron nitride (PCBN) tools are widely used for hard machining of various ferrous materials. The edge structure of the PCBN cutting tool greatly affects the machining performance. In this paper, dry turning experiments were conducted on gray cast iron with a PCBN chamfered tool. Both the cutting temperature and the cutting force were measured, and then the surface quality and tool wear mechanisms were analyzed in detail. It was found that the cutting temperature and cutting force increased with the increase in feed rate, depth of cut, and cutting speed. The surface roughness firstly decreased, and then increased with an increase in feed rate. The minimum surface roughness was obtained with a feed rate of 0.15 mm/r which exceeded the tool chamfer width. The PCBN tool wear mode was mainly micro notches on the rake face and micro chipping on the tool chamfer, while the adhesion wear mechanism was the main tool wear mechanism.

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“…However, there was minimal adhesion material on the flank face with hardly any tool wear. The observed tool wear characterizations are consistent with the literature [19].…”

Section: The Tool Wearsupporting

confidence: 91%

Section: Introductionmentioning

confidence: 99%

Experimental Investigation on the Machinability of PCBN Chamfered Tool in Dry Turning of Gray Cast Iron

Yin

Shen

et al. 2022

Processes

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“…Ra a a n a f a a a f a n a (11) In Equation (11), Ra denotes the surface roughness (µm), n stand for the spindle speed (mm/r), f represents the feed rate (mm/min), ap is the cutting depth (mm), and a0, a1, a2, a3, a4 and a5 are constants. Surface roughness measurements of the workpiece were conducted using a TR210 surface roughness measuring instrument with a sampling length of 60 mm.…”

Section: Development Of a Bi-objective Optimization Modelmentioning

confidence: 99%

“…Hard turning is a process that typically involves machining workpieces with hardness exceeding 50 HRC (Rockwell C scale). For this application, cutting tools fabricated from high-hardness materials, such as Cubic Boron Nitride (CBN) and Polycrystalline Cubic Boron Nitride (PCBN), are commonly selected [9][10][11]. These materials are not only characterized by their exceptional hardness but also demonstrate superior thermal conductivity and wear resistance [12,13], providing a significant advantage in machining high-hardness materials [14].…”

Section: Introductionmentioning

confidence: 99%

Research on Multi-Objective Process Parameter Optimization Method in Hard Turning Based on an Improved NSGA-II Algorithm

Zhang,

Wu,

2024

Processes

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To address the issue of local optima encountered during the multi-objective optimization process with the Non-dominated Sorting Genetic Algorithm II (NSGA-II) algorithm, this paper introduces an enhanced version of the NSGA-II. This improved NSGA-II incorporates polynomial and simulated binary crossover operators into the genetic algorithm’s crossover phase to refine its performance. For evaluation purposes, the classic ZDT benchmark functions are employed. The findings reveal that the enhanced NSGA-II algorithm achieves higher convergence accuracy and surpasses the performance of the original NSGA-II algorithm. When applied to the machining of the high-hardness material 20MnCrTi, four algorithms were utilized: the improved NSGA-II, the conventional NSGA-II, NSGA-III, and MOEA/D. The experimental outcomes show that the improved NSGA-II algorithm delivers a more optimal combination of process parameters, effectively enhancing the workpiece’s surface roughness and material removal rate. This leads to a significant improvement in the machining quality of the workpiece surface, demonstrating the superiority of the improved algorithm in optimizing machining processes.

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Investigation on tool wear mechanisms and machining tribology of hardened DC53 steel through modified CBN tooling geometry in hard turning

Hassan

Khan

Naveed

et al. 2023

Int J Adv Manuf Technol

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DC 53 steel has emerged as a possible replacement of AISI D2 steel possessing competitive hardness and better toughness. In the current work, turning of DC 53 steel was conducted via Xcel modified inserts by varying workpiece hardness levels (40 and 60 HRC), cutting speed (130 and 160 m/min), feed rate (0.07 and 0.112 mm/rev), and depth of cut (0.07 and 0.17 mm). A two-level 4-factor full factorial design was employed entailing 16 runs. An analysis of variance (ANOVA) was conducted to statistically analyze the effect and contributions of input parameters on response variables namely tool life, surface roughness, volume of material removed, power consumption, and machining zone temperature. Results show that the tool life, surface roughness, volume of material removed, and machining zone temperature are primarily affected by the hardness of DC53 with PCRs of ~ 96%, ~ 25%, ~ 62%, and ~ 25%, respectively. At a 40 HRC hardness value, true crater wear was observed due to continuous chips sliding at the rake face while for the workpiece having a 60 HRC, discontinuous chip formation produced less prominent crater wear. SEM images revealed complete delamination of the coating from the tool surface with adhesion and attrition wear identified as the main wear mechanisms. The formation of a groove pattern was also noticed on the flank face. The minimum surface roughness was 0.90 µm-Ra for the workpiece having a 40 HRC hardness level, and the same value was obtained for 60 HRC as well. The threshold value of the feed rate for the excellent performance of these inserts was less than 0.20 mm/rev. Additionally, the turning process proved to be productive for this material along with a lower surface roughness value in comparison to the wire EDM process.

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Improvement of tool utilization when hard turning with cBN tools at varying process parameters

Cited by 13 publications

References 12 publications

Experimental Investigation on the Machinability of PCBN Chamfered Tool in Dry Turning of Gray Cast Iron

Experimental Investigation on the Machinability of PCBN Chamfered Tool in Dry Turning of Gray Cast Iron

Research on Multi-Objective Process Parameter Optimization Method in Hard Turning Based on an Improved NSGA-II Algorithm

Investigation on tool wear mechanisms and machining tribology of hardened DC53 steel through modified CBN tooling geometry in hard turning

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