Use of Ceramic Tools in Hard Turning of Hardened AISI M2 Steel

Abstract

Tool wear and machining performance of hardened AISI M2 steel in hard turning has been studied. Ceramic tools were used in the cutting tests without coolants, and the workpiece was heat treated to increase its hardness up to Rc 60. Cutting forces, temperature, and tool wear were measured in the experiments and the effects of cutting conditions on these were investigated. Important aspects from the research are summarized as follows:I . Flank wear was the dominant wear mode on the ceramic tool insert in hard turning. In contrast, crater wear was very small due to the ceramic's high resistance against chemical reactions at high temperature. A notch was unlikely to be formed in the tool.2. The initial flank wear rate mainly depends on the feed rate. High feed rates cause a high initial flank wear rate.3. Depth of cut was the most important cutting parameter to affect cutting force variation, and the cutting force increased due to tool wear.

Comparison of tool life between ceramic and cubic boron nitride (CBN) cutting tools when machining hardened steels

“…It was concluded that the cutting speed was found to be the most important parameters on the tool life among control parameters. Similar results were obtained with previous works carried out by Lima et al (2005), Jang and Hsiao (2000), Sahin and Sur (2005), Sahin (2006), Benga and Abrao (2003), Chou et al (2002), Yang and Tarng (1998), and Davim and Figueira (2006). For example, higher speed accelerated tool wear and increased the cutting temperature of the ceramic tool when machining the hardened AISI M2 steel (Jang and Hsiao, 2000).…”

“…Similar results were obtained with previous works carried out by Lima et al (2005), Jang and Hsiao (2000), Sahin and Sur (2005), Sahin (2006), Benga and Abrao (2003), Chou et al (2002), Yang and Tarng (1998), and Davim and Figueira (2006). For example, higher speed accelerated tool wear and increased the cutting temperature of the ceramic tool when machining the hardened AISI M2 steel (Jang and Hsiao, 2000). It was reported that the cutting speed was the most dominant factor affecting the tool life when turning of hardened 100Cr6 bearing steel (Benga and Abrao, 2003, Davim 2001, Davim and Figueira 2006.…”

“…Jindal et al (1999) found that TiAlN coated tools exhibited the best cutting performance when turning Inconel 718, AISI 1045 steel and ductile iron at low and high cutting speed conditions. Jang and Hsiao (2000) studied tool the wear and machining performance of hardened AISI M2 steel (60 HRC) and determined the flank wear as the dominant wear mode on the ceramic tool insert. Depth of cut was the most important factor to affect cutting force variation, and the cutting force increased due to the tool wear.…”

Dry turning of tempered martensitic stainless tool steel using coated cermet and coated carbide tools

“…Numerous studies have been reported on the successful implementation of hard turning. Most of these studies involve work materials with hardness values in the range of 52-62 HRC and also they involve the use of ceramic, CBN and PCBN cutting tools [1][2][3][4][5][6][7][8].…”

Influence of Cutting Speed and Feed Rate on the Wear of an S-Type Mixed Ceramic Tool in Turning of AISI 4140 Hardened Steel

“…Therefore, three v c values and two values of f were adopted. Based on the results of dynamic stability tests performed by Jang & Hsiao [25] under similar conditions to those used in this work and, in order to avoid the influence of vibrations during the experiments, ap = 0.3 mm was adopted.…”