Relationship between surface roughness and chip morphology when turning hardened steel

• Autorzy: Abidi Youcef

Identyfikatory

DOI

10.30657/pea.2020.26.19

• Języki publikacji: EN

Abstrakty

EN

Hard machining is a process which has become highly recommended in manufacturing industry to replace grinding and perform production. The important technological parameters that determine this process are tool wear, machined surface roughness, cutting force and morphology of the removed chip. In this work, an attempt has been made to analyse the morphology and form of chip removed during turning of hardened steel AISI 1045 (40HRC) with mixed ceramic tool type CC650. Using a Taguchi plan L9, whose factors are cutting speed and feed rate with three levels for each. Macroscopic and microscopic results of chip morphology were correlated with these two cutting parameters additional to surface roughness. Sufficient experimental results were obtained using the mixed ceramic tool when turning of hardened steel AISI 1045 (40HRC) at high cutting speeds. Roughness of machined surface confirmed that it is influenced by feed rate. Chips show a sawtooth shape for all combinations of the experimental plan used. The chip form changed with cutting parameters variation and given an important indicator of suraface quality for industriel. Having the indicators on the surface quality from simple control of chip without stopping machining give an important advantage in order to maximize production and reduce costs.

Słowa kluczowe

EN

hard machining; AISI 1045 steel; ceramic tool; chip; surface roughness

PL

obróbka twarda; stal AISI 1045; narzędzie ceramiczne; żeton; chropowatość powierzchni

• Wydawca: Oficyna Wydawnicza Stowarzyszenia Menedżerów Jakości i Produkcji
• Czasopismo: Production Engineering Archives
• Rocznik: 2020
• Tom: Vol. 26, Iss. 3
• Strony: 92--98
• Opis fizyczny: Bibliogr. 30 poz., rys., tab.

Twórcy

autor

Abidi Youcef

• LRTAPM, Badji Mokhtar University, Annaba, P.O Box 12, 23000 Annaba, Algeria

Bibliografia

• 1.Abidi, Y., Boulanouar, L., 2017. Analyse de la correlation entre la rugosite et la vibration de coupe en usinage des aciers durcis. U.P.B. Sci. Bull., Series D, 79, 4, 157-170.
• 2.Abidi, Y., Boulanouar, L., Amirat, A., 2018. Experimental study on wear of mixed ceramic tool and correlation analysis between surface roughness and cutting tool radial vibrations during hard turning of AISI 52100 steel, Journal of Engineering Science and Technology, 13, 4, 943-963.
• 3.Anthony, X.M., 2015.Analysis of cutting force and chip morphology during hard turning of AISI D2 steel, Journal of Engineering Science and Technology, 10, 3, 282-290.
• 4.Azizi, M.W., Keblouti, O., Boulanouar, l., Yallese, M.A., 2020. Design optimization in hard turning of E19 alloy steel by analysing surface roughness, tool vibration and productivity, Structural Engineering and Mechanics, 73,5, 501-513.
• 5.Barry, J., Byrne, G., 2002, The Mechanisms of Chip Formation in Machining Hardened Steels,Transactions of the ASME, 124, 528-535.
• 6.Ben Salem, S., Bayraktar, E., Boujelbene, M.,Katundi, D., 2012. Effect of cutting parameters on chip formation in orthogonal cutting, Journal of Acheivementsin Materials and Manufacturing Engineering, 50, 1, 7-17.
• 7.Bouacha, K., Yallesse, M.A., Mabrouki, T., Rigal, J.F., 2010. Statistical analysis of surface roughness and cutting forces using response surface methodology in hard turning of AISI 52100 bearing steel with CBN tool, Int. Journal of Refractory Metals & Hard Materials, 28, 349-361.
• 8.Bouziane, A., Boulanouar, l., Azizi, M.W., Keblouti, O., Belhadi, S. 2018. Analysis of cutting forces and roughness during hard turning of bearing steel, Structural Engineering and Mechanics, 66, 3, 285-294.
• 9.Das, A., Khan, A., Mohanty, S., 2015. Optimization of machining parameters using taguchi approach during hard turning of alloy steel with uncoated carbide under dry cutting environment, International Journal of lean Thinking, 6, 2, 1-15.
• 10.Daymi, A., Boujelbene, M., Ben Salem, S., Hadj Sassi, B., Torbaty, S., 2009, Effect of the cutting speed on the chip morphology and the cutting forces, Archives of Computational Materials Science and Surface Engineering, 1, 2, 77-83.
• 11.D'Addona, D.M.,Raykar, S.J., 2016, Analysis of surface roughness in hard turning using wiper insert geometry, Procedia CIRP,41, 841-846.
• 12.Dogra, M., Sharma, V.S., Sachdeva, A., Suri, N.M., Dureja, J.S., 2010. Tool wear, chip formation and workpiece surface issues in CBN hard turning: a review, International Journal of Precision Engineering and Manufacturing, 11, 2, 341-358.
• 13.Ekinović, S., Begović, E., Fakić, B., Burić, A., Čeliković, A., 2014. Cold air dry machining Part 2: SEM and metallographic analysis of the chip, 18th Trends in the Development of Machinery and Associated Technology • TMT 2014, Budapest, Hungary, 21-24.
• 14.Elshwain, A., 2020. Comprehensive Study of Chip Morphology in Turning Hardened Tool Steel under Nitrogen Gas and Oil Mist Conditions, International Conference on Technical Sciences (ICST2019), March 2019, 1176-1182.
• 15.Keblouti, O., Boulanouar, L., Azizi, M.W., Bouziane, A., 2019. Multi response optimization of surface roughness in hard turning with coated carbide tool based on cutting parameters and tool vibration, Structural Engineering and Mechanics, 70, 4, 395-405.
• 16.Khorasani, A.M., Yazdi, M.R.S.,Safizadeh, M.S., 2012. Analysis of machining parameters effects on surface roughness: a review, Int. J. Computational Materials Science and Surface Engineering, 5, 1, 69-84.
• 17.Kumar, C.S,Patel, S.K., 2017. Experimental and numerical investigations on the effect of varying AlTiN coating thickness on hard machining performance of Al2O3-TiCN mixed ceramic inserts, Surface & Coatings Technology, 309, 266-281.
• 18.Mabrouki, T., Courbon, C., Zhang, Y., Rech, J. Nélias, D., Asad, M. Hamdi, H., Belhadi, S.,Salvatore, F., 2016. Some insights on the modelling of chip formation anditsmorphology during metal cutting operations, Comptes Rendus Mécanique, 344, 4, 335-354.
• 19.Meddour, I., Yallese, M.A., Khattabi, R., Elbah, M., Boulanouar, L., 2015. Investigation and modeling of cutting forces and surface roughness when hard turning of AISI 52100 steel with mixed ceramic tool: cutting conditions optimization, Int J Adv Manuf Technol, 77, 1387-1399.
• 20.Motorcu, A.R., 2011. Tool life performances, wear mechanisms and surface roughness characteristics when turning austenised and quenched AISI 52100 bearing steel with ceramics and CBN/TiC cutting tools, Indian Journal of Engineering & Materials Sciences, 18, 137-146.
• 21.Neslušan, M., Šípek, M., Mrázik, J.,2012. Analysis of chip formation during hard turning through acoustic emission, Materials Engineering - Materiálové inžinierstvo, 19, 1-11.
• 22.Ozel, U., Hsu, T.K.,Zeren, E., 2005. Effects of cutting edge geometry, workpiece hardness, feed rate and cutting speed on surface roughness and forces in finish turning of hardened AISI H13 steel, Int J Adv Manuf Technol, 25, 262-269.
• 23.Rajeev, D., Dinakaran, D., Kanthavelkumaran, N., Austin, N.,2016. Experimental study of surface roughness in hard turning of AISI4140 steel with coated carbide tool, World Applied Sciences Journal, 34, 10, 1310-1317.
• 24.Sadik, M.I., Lindström, B., 1995. The effect of restricted contact length on tool performance, Journal of Materials Processing Technology, 48, 275-282.
• 25.Sahoo, A.K.,Sahoon, B., 2012. Experimental investigations on machinability aspects in finish hard turning of AISI 4340 steel using uncoated and multilayer coated carbide inserts, Measurement, 45, 2153-2165.
• 26.Vyas, A., Shaw, M.C., 1999. Mechanics of saw-tooth chip formation in metal cutting”, Journal of Manufacturing science and Engeneering, 121(2), 163-172.
• 27.Watmon, T.B., Ijeh, A.C., 2010. Coating cutting tools with hard substance lowers friction coefficient and improves tool life - a review, Proceedings of the International Multiconference of Engineer and Computer Scientists, 3, Hong Kong, March 17-19.
• 28.Yadav, L., 2016. Analysis of chip formation during hard turning through acoustic emission. International Journal of Mechanical Engineering, 4, 11, 34-38.
• 29.Zhang, S., Li, J., Zhu, X., Lv, H., 2013. Saw-tooth chip formation and its effect on cutting force fluctuation in turning of inconel 718, International Journal of Precision Engineering and Manufacturing, 14, 957-963.
• 30.Zhang, X.P., Wu, S.B., 2016. Chip control in the dry machining of hardened AISI 1045 steel, Int J Adv Manuf Technol, 88, 3319-3327.

Uwagi

Opracowanie rekordu ze środków MNiSW, umowa Nr 461252 w ramach programu "Społeczna odpowiedzialność nauki" - moduł: Popularyzacja nauki i promocja sportu (2021).