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Surface integrity on hardened steel parts produced by hybrid machining sequences

Wybrane pełne teksty z tego czasopisma
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Warianty tytułu
Języki publikacji
EN
Abstrakty
EN
Purpose: Of this paper is the investigation of surface integrity generated in hard turning and subsequent finish abrasive machining. The primary reason for undertaking this problem was insufficient magnitude of compressive residual stresses after hard turning which determines the fatigue resistance of highly loaded transmission parts. Design/methodology/approach: Employed uses 2D and 3D description of the surface roughness/surface microstreometry and the X-ray diffraction method for measurements of residual stresses. The main scope of this research program is to record the relevant changes of surface layer features resulting from the application of finish abrasive passes. Findings: Can be distinguished into two groups. First, finish belt grinding produces the residual stresses with the maximum value of-1000 MPa, which is satisfactory for improving fatigue life. Second, the bearing properties improve due to displaying negative values of the skew. Research limitations/implications: Deal with the identification range of 3D roughness parameters and the lack of modern equipment for robust measurements of residual stresses: Future research should be focused on the stronger correlation between technological and exploitation properties of the surfaces produced by hard and abrasive technologies. However, it needs more detailed inputs from automotive industry. Practical implications: Are related to the automotive industry, especially to manufactures of such transmission elements as synchronizing cones/planes on gear wheels. The sequences of new hybrid machining processes are partly verified in terms of industry needs (machining conditions, machine tools, special equipment, cutting and abrasive tools). Originality/value: Of this industry-oriented contribution is based on the aggregating hard cutting and abrasive machining processes. The practical value of the paper is that it proposes a very beneficial machining process for highly loaded hardened parts.
Rocznik
Strony
654--661
Opis fizyczny
Bibliogr. 25 poz., wykr., tab., il.
Twórcy
autor
autor
autor
  • Department of Manufacturing Engineering and Production Automation, Opole University of Technology, Poland, joel.rech@enise.fr
Bibliografia
  • [1] A. M. Abrao, D. K. Aspinwall, The surface integrity of turned and ground hardened bearing steel, Wear 196 (1996) 279-284.
  • [2] G. C. Benga, A. M. Abrao, Turning of hardened 100Cr6 bearing steel with ceramic and PCBN cutting tools, Journal of Materials Processing Technology 143-144 (2003) 237-241.
  • [3] Y. K. Chou, Ch. J. Evans, M. M. Barash, Experimental investigation on CBN turning of hardened AISI 52100 steel, Journal of Materials Processing Technology 124 (2002) 274-283.
  • [4] C. Garcia-Rosales, X-ray diffraction measurements and data analysis, personal communication, CEIT & TECNUN, Universidad de Navarra, San Sebastian, Spain, 2006.
  • [5] W. Grzesik, T. Wanat, Comparative assessment of surface roughness produced by hard machining with mixed ceramic tools including 2D and 3D analysis, Journal of Materials Processing Technology 169 (2005) 364-371.
  • [6] W. Grzesik, T. Wanat, Surface finish generated in hard turning of quenched alloy steel parts using conventional and wiper ceramic inserts, International Journal of Machine Tools and Manufacture 46/15 (2006) 1988-1995.
  • [7] W. Grzesik, S. Brol, Hybrid approach to surface roughness evaluation in multistage machining processes, Journal of Materials Processing Technology 134 (2003) 265-272.
  • [8] W. Grzesik, J. Rech, T. Wanat, Surface integrity of hardened steel parts in hybrid machining operations, Journal of Achievements in Materials and Manufacturing Engineering 18 (2006) 367-370.
  • [9] Y. B. Guo, J. Sahni, A comparative study of hard turned and cylindrically ground white layers, International Journal of Machine Tools and Manufacture,44 (2004) 135-145.
  • [10] A. Jourani, M. Dursapt, H. Hamdi, J. Rech, H. Zahouani, Effect of the belt grinding on the surface texture: modeling of the contact and abrasive wear, Wear 259 (2005) 1137-1143.
  • [11] J. Kaczmarek, E. Kulawik, New approach to the characteristics of surface microstereometry on the basis of facing, Advances in Technology Machines and Equipment 23 (1999) 55-70.
  • [12] F. Klocke, E. Brinksmeier, K. Weinert, Capability profile of hard cutting and grinding processes, CIRP Annals 54 (2005) (in press).
  • [13] W. König, M. Klinger, R. Link, Machining hard materials with geometrically defined cutting edges-field of applications and limitations, CIRP Annals 39 (1990) 61-64.
  • [14] J. Kundrak, V. Bana, K. Gyani, 3D Topography of hard turned and ground surfaces, Proceedings of the 3rd International Congress of Precision Machining ICPM'2005, Vienna, 2005, 195-202.
  • [15] J. G. Lima, R. F. Ávila, M. Faustino, J. P. Davim, Hard turning: AISI 4340 high strength low alloy steel and AISI D2 cold work tool steel, Journal of Materials Processing Technology 169 (2005) 388-395.
  • [16] M. Liu, J.-I. Takagi, A. Tsukuda, Effect of tool nose radius and tool wear on residual stress distribution in hard turning of bearing steel, Journal of Materials Processing Technology 150 (2004) 234-241.
  • [17] I. Mankova, G. Markova, Evaluation of surface microgeometry when grinding and finish turning of hardened steel, Proceedings of the 3rd International Congress of Precision Machining ICPM'2005, Vienna, 2005, 231-237.
  • [18] D. Novovic, R. C. Dewes, D. K. Aspinwall, W. Voice, P. Bowen, The effect of machined topography and integrity on fatigue life, International Journal of Machine Tools and Manufacture 44 (2004) 125-134.
  • [19] J. Rech, A. Moisan, Surface integrity in finish hard turning of case-hardened steels, International Journal of Machine Tools and Manufacture 43 (2003) 543-550.
  • [20] H. K. Tönshoff, C. Arendt, R. Ben Amor, Cutting of hardened steel, CIRP Annals 49 (2000) 547-566.
  • [21] H. K. Tönshoff, T. Friemuth, C. Marzenell, Properties of honed gears during lifetime, CIRP Annals 49 (2000) 431-434.
  • [22] J. M. Zhou, M. Andersson, J. E. Stahl, Identification of cutting errors in precision hard turning process, Journal of Materials Processing Technology 153-154 (2004) 746-750.
  • [23] New developments in hard part machining, 2002 (www.SandvikCoromant.com).
  • [24] MICROFINISH® Machining of transmission and engine parts, ball and roller bearings, thrusts and sealing faces (www.thielenhaus.us).
  • [25] X-Ray Diffraction Systems (www.emsl.pnl.gov/capabs).
Typ dokumentu
Bibliografia
Identyfikator YADDA
bwmeta1.element.baztech-article-BWAN-0004-0024
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