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

Abstract

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.

Analysis of chip compression ratio in turning of polyoxymethylene copolymer

“…As given in Equation 1, the resulting CCR in turning is higher than 1 because the actual chip thickness is greater than the corresponding un-deformed chip thickness, due to the frictional conditions existing at the chip-tool interface and the plastic deformation of the chip [14]. Higher CCR values require more work to carry out the process [10] and therefore indicate a higher demand for plastic energy for chip formation [3]. This means that the chip has encountered tremendous constraints in sliding across the rake face of the tool, affecting chip movement, and has thus become thicker and vice versa [7].…”

“…Chandra Behera et al [3] conducted experimental research to grasp chip formation mechanisms in Inconel 718 turning using metallographic techniques. Kuruc et al [10] analyzed the impact of feed rate and cutting speed on plastic deformation and CCR while turning C45 medium carbon steel and 62SiMnCr4 tool steel.…”

Research on Roughness and Microhardness of C45 Material Using High-Speed Machining

“…The significance and importance of this issue are confirmed by the publications of the authors at the global level. The authors [1] dealt with the issue of the influence of cutting parameters on chip compression and plastic deformation in the turning process of carbon and tool steel. From the conducted research, cutting parameters were selected, through which it is possible to achieve an increase in process efficiency for the investigated materials and, at the same time, an improvement in surface integrity with the identification of the lowest possible plastic deformation in the cutting zone.…”

Effect of Heat Treatment on the Resulting Dimensional Characteristics of the C45 Carbon Steel after Turning

“…The accompanying phenomenon of machinability is the dimensional accuracy and roughness achieved during machining. Furthermore, the material of the cutting wedge, and the type of coating also influence the resulting surface parameters [4][5][6][7]. In technical practice, the machining of semi-finished products is streamlined to ensure the efficiency and economy of production.…”