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1

Analysis of the OCHN3MFA steel in terms of cutting forces and cutting material flank wear mechanisms in hard turning processes

Majerík Jozef, Barényi Igor, Pokorný Zdenek, Sedlák Josef, Neumann Vlastimil, David Dobrocký, Jaroš Aleš, Krbata Michal, Jambor Jaroslav, Kusenda Roman, Sagan Miroslav, Procházka Jiri

Bulletin of the Polish Academy of Sciences. Technical Sciences

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2021

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Vol. 69, nr 6

art. no. e139203

EN

This article deals with the effect of selected machining parameter values in hard turning of tested OCHN3MFA steel in terms of SEM microstructural analysis of workpiece material, cutting forces, long-term tests, and SEM observations of flank wear VB and crater wear KT of used changeable coated cemented carbide cutting inserts in the processes of performed experiments. OCHN3MFA steel was selected as an experimental (workpiece) material. The selected experimental steel was analyzed prior to hard turning tests to check the initial microstructure of bulk material and subsurface microstructure after hard turning and chemical composition. Study of workpiece material’s microstructure and worn cemented carbide cutting inserts was performed with Tescan Vega TS 5135 scanning electron microscope (SEM) with the X-Ray microanalyzer Noran Six/300. The chemical composition of workpiece material was analyzed with Tasman Q4 surface analyzer. All hard turning experiments of the used specimens were performed under the selected machining parameters in the SU 50A machine tool with the 8th selected individual geometry of coated cementite carbide cutting inserts clamped in the appropriate DCLNR 2525M12-M type of cutting tool holder. During the hard turning technological process of the individual tested samples made of OCHN3MFA steel, cutting forces were measured with a Kistler 9257B piezoelectric dynamometer, with their subsequent evaluation using Dynoware software. After the long-term testing, other experiments and results were also realized, evaluating the influence of selected machining parameters with different cutting insert geometry on the achieved surface quality.

2

A Frontier Statistical Approach Towards Online Tool Condition Monitoring and Optimization for Dry Turning Operation of SAE 1015 Steel

Moganapriya Chinnasamy, Rajasekar Rathanasamy, Gobinath Velu Kaliyannan, Prabhakaran Paramasivam, Jaganathan Saravana Kumar

Archives of Metallurgy and Materials

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2021

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Vol. 66, iss. 3

901--909

EN

This research study intends to develop an online tool condition monitoring system and to examine scientifically the effect of machining parameters on quality measures during machining SAE 1015 steel. it is accomplished by adopting a novel microflown sound sensor which is capable of acquiring sound signals. The dry turning experiments were performed by employing uncoated, TiAlN, TiAlN/WC-C coated inserts. The optimal cutting conditions and their influence on flank wear were determined and predicted value has been validated through confirmation experiment. During machining, sound signals were acquired using Ni DAQ card and statistical analysis of raw data has been performed. Kurtosis and I-Kaz coefficient was determined systematically. The correlation between flank wear and I-Kaz coefficient was established, which fits into power-law curve. The neural network model was trained and developed with least error (3.7603e-5). It reveals that the developed neural network can be effectively utilized with minimal error for online monitoring.

3

The effect of parameters and geometry cutting edge after turning of the duplex cast steel on the maximum tool flank wear

Dyl Tomasz Cyryl

Journal of KONES

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2019

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Vol. 26, No. 2

29--35

EN

It is important to shape the required properties of the surface layer in the technological process. This issue is an important problem due to the ability of the kinematic pair elements to the required reliable operation of machine parts. The latest generation devices work with increasing operational loads. This forces the search forever-newer construction materials or innovative manufacturing engineering technologies that would ensure high reliability and durability of machine components. For mechanical engineering, continue to be used on steel structures of machine parts. In the petrochemical and shipbuilding industry, stainless steels are very poplars. Those materials are used in the constructions of seawater and acid installations. Currently, a newer material with more favourable properties is two-phase stainless steel. This is the so-called duplex steel. It can be applied to pump shafts in acid or seawater solutions. Duplex cast steel is a difficult-to-cut material. It is important to determine the effect of cutting parameters on the surface quality of the shafts and wear of cutting edge. Traditional methods of finishing surface treatment of shafts are machining (turning, grinding, superfinishing). Considering the possibilities of equipping a marine power plant workshop, it would be best to use machining by turning. The paper specifies the relationship between the wear of the cutting edge and the geometrical structure of the machined surface as well as the type of tool material used and the shape of the cutting inserts.

4

Thermal and tool wear characterization of graphene oxide coated through magnetorheological fluids on cemented carbide tool inserts

Thiyagu M., Karunamoorthy L., Arunkumar N.

Archives of Civil and Mechanical Engineering

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2019

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Vol. 19, no. 4

1043--1055

EN

The proposed work is about the investigation of nano-textured tool insert with magnetor-heological-based graphene coating process. The comparative study on nano-textured car-bide insert with unpolished one for turning duplex stainless steel (S31803/2205) is made by conducting number of experiments with Box–Behnken design using response surface methodology. An array of sensor based on the conductive element of chromel and alumel core integrated through DC magnetron sputtering on the rake surface of the tool insert. The performance of the proposed sensor was evaluated from the obtained thermo-electromotive force on tool chip contact interference and the temperature measurements taken at the contours of multiple points with respect to the tool wear. Results obtained clarify that with the rise in cutting tool temperature leads to the rise in tool wear based on the adhesion and abrasion. It has been found that the graphene coated tool inserts provides high wearable resistances with flank wear of 0.298 mm at 21st pass. The cutting tool temperature is found to spread uniformly with a value of 202 8C for graphene coated inserts for cutting speed of 55 m/min. Microstructural images taken proved that the formation of cementite and carbides with inter metallic compounds (IMCs) produced during the tool chip interface leads to the strengthening of tool tip in reducing the tool-wear. Also the occurrence of ultrafine grain boundaries on the tool tip occurs increasing the formation of covalent bonds in providing the robust resistance against tool wears.

5

Influence of Cutting Fluid Flow Rate and Cutting Parameters on the Surface Roughness and Flank Wear of TiAlN Coated Tool in Turning AISI 1015 Steel Using Taguchi Method

Moganapriya C., Rajasekar R., Ponappa K., Venkatesh R., Karthick R.

Archives of Metallurgy and Materials

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2017

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Vol. 62, iss. 3

1827--1832

EN

This paper presents the influence of cutting parameters (Depth of cut, feed rate, spindle speed and cutting fluid flow rate) on the surface roughness and flank wear of physical vapor deposition (PVD) Cathodic arc evaporation coated TiAlN tungsten carbide cutting tool insert during CNC turning of AISI 1015 mild steel. Analysis of Variance has been applied to determine the critical influence of cutting parameters. Taguchi orthogonal test design has been employed to optimize the process parameters affecting surface roughness and tool wear. Depth of cut was found to be the most dominant factor contributing to high surface roughness (67.5%) of the inserts. However, cutting speed, feed rate and flow rate of cutting fluid showed minimal contribution to surface roughness. On the other hand, cutting speed (45.6%) and flow rate of cutting fluid (23%) were the dominant factors influencing tool wear. The optimum cutting conditions for desired surface roughness constitutes the following parameters such as medium cutting speed, low feed rate, low depth of cut and high cutting fluid flow rate. Minimal tool wear was achieved for the following process parameters such as low cutting speed, low feed rate, medium depth of cut and high cutting fluid flow rate.

6

Finite element analysis of influence of flank wear evolution on forces in orthogonal cutting of 42CrMo4 steel

Madajewski M., Nowakowski Z.

Archives of Mechanical Technology and Materials

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2017

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Vol. 37

58--64

EN

This paper presents analysis of flank wear influence on forces in orthogonal turning of 42CrMo4 steel and evaluates capacity of finite element model to provide such force values. Data about magnitude of feed and cutting force were obtained from measurements with force tensiometer in experimental test as well as from finite element analysis of chip formation process in ABAQUS/Explicit software. For studies an insert with complex rake face was selected and flank wear was simulated by grinding operation on its flank face. The aim of grinding inset surface was to obtain even flat wear along cutting edge, which after the measurement could be modeled with CAD program and applied in FE analysis for selected range of wear width. By comparing both sets of force values as function of flank wear in given cutting conditions FEA model was validated and it was established that it can be applied to analyze other physical aspects of machining. Force analysis found that progression of wear causes increase in cutting force magnitude and steep boost to feed force magnitude. Analysis of Fc/Ff force ratio revealed that flank wear has significant impact on resultant force in orthogonal cutting and magnitude of this force components in cutting and feed direction. Surge in force values can result in transfer of substantial loads to machine-tool interface.

7

A novel approach to enhance performance of multilayer coated carbide insert in hard turning

Shihab S. K., Khan Z. A., Siddiquee A. N., Khan N. Z.

Archive of Mechanical Engineering

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2015

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Vol. LXII, nr 4

539--552

EN

Flank wear of multilayer coated carbide (TiN/TiCN/Al2O3/TiN) insert in dry hard turning is studied. Machining under wet condition is also performed and flank wear is measured. A novel micro-channel is devised in the insert to deliver the cutting fluid directly at the tool-chip interface. Lower levels of cutting parameters yield the minimum flank wear which is significantly affected by cutting speed and feed rate. In comparison to dry and wet machining, insert with micro-channel reduces the flank wear by 48.87% and 3.04% respectively. The tool with micro-channel provides saving of about 87.5% in the consumption of volume of cutting fluid and energy.

PL

W pracy przedstawiono badania nad zużyciem krawędzi skrawającej wielowarstwowej płytki z ceramiki narzędziowej (TiN/TiCN/Al2O3/TiN) w toczeniu twardym na sucho. Badano także zużycie krawędzi skrawającej w warunkach toczenia na mokro. Nowatorskim rozwiązaniem było zastosowanie mikrokanału w płytce skrawającej, przez który płyn smarny dostarczany jest bezpośrednio do styku między narzędziem i wiórem. Uzyskany tą drogą niższy poziom parametrów skrawania zapewnia minimalne zużycie krawędzi skrawającej, na które w istotny sposób wpływają prędkość skrawania i szybkość posuwu. W porównaniu do warunków toczenia na sucho i na mokro, zastosowanie mikrokanału zmniejsza zużycie krawędzi skrawającej o odpowiednio 48,87% i 3,04%. Narzędzie z mikrokanałem zapewnia także oszczędność zużycia płynu smarnego i energii o ok. 87,5%.

8

Development and machinability assessment in turning Al/SiCp-metal matrix composite with multilayer coated carbide insert using Taguchi and statistical techniques

Sahoo A. K., Pradhan S., Rout A. K.

Archives of Civil and Mechanical Engineering

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2013

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Vol. 13, no. 1

27--35

EN

This paper presents the development of Al/SiCp (10% weight) metal matrix composite through a conventional casting process and studied its machinability characteristics in turning using multilayer TiN coated carbide insert under dry environment based on Taguchi's L9 orthogonal array. Abrasion is found to be the dominant wear mechanism from the experimental study. Continuous fragmented saw tooth type of chip obtained during machining of Al/SiCp-MMC under dry environment. The colour of chip changes from metallic to partial blue and built-up-edge formation is noticed at extreme parametric conditions. Cutting speed is observed to be the most significant variable affecting the flank wear. Feed is found to be the most significant parameter for surface roughness. The regression models are highly significant because of higher R2 value. The experimental and predicted values are very close to each other. Using grey relational analysis, the optimal parametric combination for multi-responses is found to be v3-f1-d3 and is greatly improved and noticed to be efficient while machining Al/SiCp-MMC.

9

Performance of cryogenically treated CBN inserts on difficult to cut materials during turning

Thamizhmanii S., Hasan S.

Journal of Achievements in Materials and Manufacturing Engineering

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2012

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Vol. 55, nr 2

829--834

EN

Machining of materials is recognized as removing unwanted materials by using different cutting inserts. In this research, cutting inserts used are CBN inserts and treated cryogenically at -196°C in liquid nitrogen chamber. The inserts are subjected to 30 hours of treatment in controlled atmosphere. The materials used are Titanium and AISI 440 C hard Martensitic Stainless steel. The cutting parameters are cutting velocity 30, 40 and 50 m/min with feed rate of 0.05, 0.10 and 0.15 mm/rev and depth of cut of 0.05, 0.75 and 1.00 mm. The performance evaluated was tool wear, surface roughness. Cryogenically treated CBN inserts produced less tool wear on titanium than AISI 440 C Martensitic stainless steel. The roughness produced was low at high cutting speed with low feed rate. Flank wear was not progressive and varied. In turning AISI 440 C stainless steel, built up edge formed in all cutting speed which is a common phenomena and lead to crater wear formation. The chips produced were saw tooth chips by both materials.

10

Performance of deep cryogenically treated and non-treated PVD inserts in milling

Thamizhmani S., Nagib M., Sulaiman H.

Journal of Achievements in Materials and Manufacturing Engineering

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2011

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Vol. 49, nr 2

460--466

EN

Purpose: The purpose of the research was to analysis the tool performance between cryogenic treated and non-treated PVD inserts by milling process on Inconel 718 material in terms of surface roughness and tool wear. Design/methodology/approach: The methodology adopted is milling process with various cutting parameters like cutting speed, feed rate and constant depth of cut. Cutting speeds are 20,30,40 m/min with feed rate 0.05, 0.08 & 0.10 mm/ tooth and constant depth of cut is 0.50 mm. Findings: From the experimental work, the results were encouraging and performance is analysed on surface roughness and tool wear. Cryogenic treated inserts performed better than non treated inserts. Treated PVD inserts produced low surface roughness at high cutting speed with low feed rate. PVD treated inserts formed low flank wear where as untreated inserts formed more flank wear. Chips produced were saw tooth chips. Research limitations/implications: There are some limitations in carrying out this work due to machine vibration. There was a constraint in measuring the crater wear of the tool. Originality/value: This experimental work will help other researchers to follow on flank and crater wear using cryogenic treatment. This process can be used for difficult to cut materials like Titanium.

11

Measurement of tool flank wear with the use of white light interferometer

Zawada-Tomkiewicz A., Storch B.

Pomiary Automatyka Kontrola

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2010

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R. 56, nr 8

950-953

EN

Tool geometry is one of the key factors influencing the quality of the cutting process. Usually the geometry is described for a new tool and the changes in it during cutting are explained with the use of tool wear indexes. They are quite easy to measure when the wear is significant. However, for the finishing processes the location of tool edge and the roughness of the tool edge are the most important factors, which are difficult to measure mainly because of a very developed surface of wear land with a number of difficult to measure points. In the paper, the Talysurf CCI 6000 was used to measure tool cutting wedge geometry, flank wear and roughness of the cutting edge. Measurement of tool irregularities with the use of CCI 6000 was rapid but its application was limited for measurement tool geometry in a state of wear.

PL

Geometria narzędzia jest kluczowym czynnikiem wpływającym na jakość procesu skrawania. Geometria podawana jest dla narzędzia nowego, natomiast zmiany na ostrzu podczas jego pracy opisywane są za pomocą wskaźników zużycia ostrza zdefiniowanych w normie ISO 3685. Wyznaczenie wartości wskaźników zużycia ostrza nie nastręcza wielu problemów, gdy wielkość ta dotyczy zużycia na granicy trwałości narzędzia [1-5]. Natomiast dla obróbki wykończeniowej decydującym o jakości procesu jest położenie krawędzi skrawającej (wymiar geometryczny przedmiotu) oraz chropowatość krawędzi skrawającej (mikrochropowatość powierzchni obrobionej) [6-9]. Charakterystyki te są trudne do zmierzenia ze względu na rozwiniętą powierzchnię zużycia ostrza oraz występujące mikropowierzchnie o znacznym nachyleniu. W artykule zaprezentowano pomiar geometrii narzędzia, zużycia na powierzchni przyłożenia oraz chropowatości powierzchni obrobionej przy zastosowaniu Talysurf CCI 6000 [10]. Pomiar przy użyciu CCI 6000 okazał się niezwykle szybki i dokładny. Ze względu na ograniczony zakres pomiaru wielkości, zarówno w pionie jak i w poziomie, dominującym czynnikiem określającym możliwości pomiarowe okazało się precyzyjne ustawianie ostrza podczas pomiaru.

12

Measurement of surface roughness and flank wear on hard martensitic stainless steel by CBN and PCBN cutting tools

Thamizhmnaii S., Hasan S.

Journal of Achievements in Materials and Manufacturing Engineering

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2008

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Vol. 31, nr 2

415-421

EN

Purpose: The experiments with different operating parameters using CBN and PCBN tools on hard AISI 440 C material were investigated in this paper. Design/methodology/approach: In this research AISI 440 C stainless was used under hard condition. The cutting tools are having three cutting edges and each edge repeated for 5 times. The test conducted by each cutting edge was termed as trail 1, 2, 3, 4 & 5. The length of cutting was 150 mm and each trail. The surface roughness and flank wear, crater wear and BUE were measured by SEM. Findings: The surface roughness was low by CBN at high turning cutting speed and the flank wear was high. The surface roughness was high by PCBN tool than CBN tool and flank wear recorded was low for PCBN tool than CBN tool. The chips produced were saw tooth in all operating parameters. The CBN tool was unable to withstand heat at cutting zone and hence more flank wear occurred. The PCBN tool sustained the temperature and less tool wear occurred. More crater wear formed on PCBN tools where as CBN tool produced less crater wear. The formation of crater wear on the rake face was due to rough surface of the saw tooth chips. Practical implications: The investigation results will provide useful information to applying CBN and PCBN cutting tools in hard turning stainless steels. Originality/value: Hard turning is a latest technology and possible to turn all hard materials. The hard turning produce net shaped products and reduces machining time, low cost per products, etc. The difficult to cut materials like stainless steels was turned by super hard cutting tools like CBN and PCBN to achieve good urface roughness, dimensional control and reduced tool wear.

13

Tool flank wear analyses on martensitic stainless steel by turning

Thamizhmnaii S., Bin Omar B., Saparudin S., Hasan S.

Archives of Materials Science and Engineering

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2008

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Vol. 32, nr 1

41-44

EN

Purpose: Purpose of this research was to demonstrate tool wear by hard turning of martensitic stainless steel and this material is pronounced as difficult to machine material. The evaluation was done using CBN cutting tool on SS 440 C stainless steel with hardness between 45 to 55 HRC. Design/methodology/approach: Turning parameters like cutting speed, feed rate and depth of cut was used. The turning was carried out dry process. Findings: The flank wear was caused by abrasive action between cutting tool and work piece. The heat generated between work piece and tool tip help to form built up edge. The generated heat was conducted easily due to low thermal conductivity of the work piece material. At low cutting speed of 125 m / min with high feed rate of 0.125 mm / rev and 1.00 mm DOC. Research limitations/implications: It was difficult to decide the operating parameters due to physical and chemical properties of the material. Operating at high cutting speed would result in tool flank wear, surface damage and other wears. Originality/value: The originality of this paper lies with conducting experiment and finding optimum operating parameters. The other researches can have as reference.

14

Tool wear prediction in machinning by using the adaptive neuro-fuzzy system

Zuperl U., Milfelner M., Cus F.

International Journal of Applied Mechanics and Engineering

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2004

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Vol. 9, no spec.

73-78

EN

The focus of this paper is to develop a reliable method to predict flank wear during end milling process. A neural-fuzzy scheme is applied to perform the prediction of flank wear from cutting force signals. In this contribution we also discussed the construction of a ANFIS system that seeks to provide a linguistic model for the estimation of tool wear from the knowledge embedded in the neural network. Machining experiments conducted using the proposed method indicate that using an appropriate force signals, the flank wear can be predicted within 4% of the actual wear for various end-milling conditions.

15

Cutting performance of new high-speed steels with PVD wear resistant coatings.

Richter J.

Inżynieria Materiałowa

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2001

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R. XXII, nr 5

780-783

EN

Cutting performance of uncoated and coated new high-speed steels containing Ti and/or Nb were compared with that of the classical SW7M (M2) grade and steel produced by powder metallurgy methods. The resulting flank wear and crater depth were analysed, the worn surfaces were observed using scanning electron microscope. Certain phenomena (groove on flank face, build up edge formation) developed in way depending of the steel substrate.

PL

W pracy porównano własności skrawne niepowlekanych i powlekanych nowych stali szybkotnących z Ti i/lub Nb z gatunkiem SW7M i stalą wyprodukowaną metodami metalurgii proszków. Przeanalizowano wielkość starcia na powierzchni przyłożenia i głębokość krateru; efekty zużycia obserwowano za pomocą SEM. Pewne zjawiska (tworzenie narostu, rowka na powierzchni przyłożenia) przebiegały odmiennie w badanych stalach.