Turning conditions of Ck 45 steel with alternate hardness zones

• Autorzy: Stoic A. , Kopac J. , Ergic T. , Duspar M.
• Języki publikacji: EN

Abstrakty

EN

Purpose: of this paper is investigation of dynamic impacts on cutting edge during machining of locally hardened steel. Alteration of hardness on a single work piece is a source of impact on tool, which could lead to breakage of cutting tool and work piece surface damage in turning. Influence of material properties (primary hardness) is important when work piece is hardened locally by induction and part of material is soft annealed. Design/methodology/approach: Experimental tests of cutting outputs have been done on specimens after induction hardening to evaluate the rate of variation of cutting forces, surface roughness and chip formation because of hardness alteration. Measured data of main cutting force were analyzed in frequency and time domain. Findings: It was found that chip formation condition, chip thickness and chip shape depends on cutting forces alteration in transition areas in the range of 10 to 15%. Much higher alteration of force signal is recorded when machining is performed with low depth of cutting value as a result of backlash in system. The most important value of cutting force correlates with depth of cutting, and roughness correlates oppositely to the hardness. Research limitations/implications: Results and findings presented in this paper are qualitative and might be slightly different in other cutting condition (e.g. other heat treatable steels or other hardening techniques or other single cutting point processes). There is evident force value alteration in the transition (hard to soft state) zone. Practical implications: Surface roughness is a consequence of both cutting impacts and of tool/work piece loading condition. Originality/value: Originality of the paper is in analysis for stability of turning to heat treatable steel influenced with alternating work piece hardness. It was recorded edge loading shock overcome from hard to soft machining. It was recorded and analyzed self-exited vibration. A new type of chips: horseshoe-type was found.

Słowa kluczowe

EN

machining; mechanical properties; dynamic properties; depth of cutting

PL

obróbka; właściwości mechaniczne; właściwości dynamiczne; głębokość skrawania

• Wydawca: International OCSCO World Press
• Czasopismo: Journal of Achievements in Materials and Manufacturing Engineering
• Rocznik: 2009
• Tom: Vol. 34, nr 1
• Strony: 87--94
• Opis fizyczny: Bibliogr. 20 poz., rys., tabl.

Twórcy

autor

Stoic A.

autor

Kopac J.

autor

Ergic T.

autor

Duspar M.

• Faculty of Mechanical Engineering, University of Osijek, Trg I. B. Mažuranić 2, 35000 Slavonski Brod, Croatia,

Bibliografia

• [1] TI El-Wardany, HA Kishawy, MA Elbestawi, Surface integrity of die material in high speed hard machining, Parts 1 & 2: Micro hardness variations and residual stress, ASME, Journal of Manufacturing Science and Engineering 122 (2000) 620-641.
• [2] M. A. Yallesea, K. Chaouib, N. Zeghibb, L. Boulanouarb, J. F. Rigalc, Hard machining of hardened bearing steel using cubic boron nitride tool, Journal of Materials Processing Technology 209/2 (2009) 1092-1104.
• [3] MA. Elbestawi, AK Srivastava, T I X A.El-Wardany, A model for chip formation during machining of hardened steel, Annals of CIRP 45 (2000) 71-76.
• [4] G. Poulachon, AL. Moisan Hard turning: chip formation mechanisms and metallurgical aspects. ASME Journal of Manufacturing Science and Engineering 122 (2000) 406-412.
• [5] T. Özela, Y. Karpata, L. Figueirab, J. P. Davimb, Modelling of surface finish and tool flank wear in turning of AISI D2 steel with ceramic wiper inserts, Journal of Materials Processing Technology 189/1-3 (2007) 192-198.
• [6] MA. Elbestawi, L. Chen, CE Becze, TI El-Wardany, High-speed milling of die and molds in their hardened state, Annals of CIRP 46 (1997) 57-62.
• [7] D. I. Lalwani, N. K. Mehta, P. K. Jain, Experimental investigations of cutting parameters influence on cutting forces and surface roughness in finish hard turning of MDN250 steel, Journal of Materials Processing Technology 206/1-3 (2008) 167-179.
• [8] N. K. Chandiramani, T. Pothala, Dynamics of 2-dof regenerative chatter during turning, Journal of Sound and Vibration 290 (2006) 448-464.
• [9] J. Hua, D. Umbrello, R. Shivpuri, Investigation of cutting conditions and cutting edge preparations for enhanced compressive subsurface residual stress in the hard turning of bearing steel, Journal of Materials Processing Technology 171 (2006) 180-187.
• [10] J. M. Zhou, M. Andersson, J. E. Ståhl, Identification of cutting errors in precision hard turning process, Journal of Materials Processing Technology 153-154 (2004) 746-750.
• [11] V. Savas, C. Ozay, Analysis of the surface roughness of tangential turn-milling for machining with end milling cutter, Journal of Materials Processing Technology 186 (2007) 279-283.
• [12] W. X. Tang, Q. H. Song, S. Q. Yu, S. S. Sun, B. B. Li, B. Du, X Ai, Prediction of chatter stability in high-speed finishing end milling considering multi-mode dynamics, Journal of Materials Processing Technology 209/5 (2009) 2585-2591.
• [13] J. L. Andreasen, L.De Chifre, Automatic Chip-Breaking Detection in Turning by Frequency Analysis of Cutting Force, Annals of CIRP 42 (1993) 45-48.
• [14] J. T. Horng, N. M. Liu, K. T. Chiang, Investigating the machinability evaluation of Hadfield steel in the hard turning with Al2O3/TiC mixed ceramic tool based on the response surface methodology, Journal of Materials Processing Technology 208 (2008) 532-541.
• [15] Slewing rings, http://www.strojna-obrada.hr/production_program/slewing_rings/default.aspx, access 2009.
• [16] J. Kopac, S. Šali, Tool wear monitoring during the turning process. Journal of Materials Processing Technology 113 (2001) 312-316.
• [17] J. Kopac, A. Stoic, M. Lucic, Dynamic instability of the hard turning process, Journal of Achievements in Materials and Manufacturing Engineering 17 (2006) 373-376.
• [18] M. C. Cakir, Y. Isik, Finite element analysis of cutting tools prior to fracture in hard turning operations, Materials and Design 26 (2005) 105-112.
• [19] T. Ergic, A. Stoic, P. Konjatic, Dynamic Analysis Of Machine And Workpiece Instability In Turning, Proceedings of the 4th DAAAM International Conference ATDC, Slavonski Brod, 2005, 497-502.
• [20] R. Mahdavinejad, Finite element analysis of machine and workpiece instability in turning, International Journal of Machine Tools & Manufacture 45 (2005) 753-760.