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Analysis of the compromise between cutting tool life, productivity and roughness during turning of C45 hardened steel

Abidi Youcef

Production Engineering Archives

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2021

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Vol. 27, Iss. 1

30--35

EN

Tool wear and surface roughness as performance indexes are considered to be the most important in terms of hardened materials’ machinability. The best combination of cutting parameters which enhances the compromise between tool life, productivity and machined surface quality contribute to benefice on production cost, which makes manufacturing industry interested in it. The aim of this research is to investigate the life of ceramic cutting tool and machining productivity together with surface roughness during turning of hardened steel C45, with focus on the selection of the optimal cutting parameter combination. The experiments are carried out based on uni-factorial planning methodology of cutting speeds and feed rates. The results show that the mixed ceramic tool is suitable for turning hardened steel C45 (40 HRC) and the conclusion is that it performed well in terms of tool life, productivity and surface quality at a combination of cutting speed (200 m/min), feed (0.08 mm/rev) and depth of cut (0.3 mm). Additionally, a tool life model has been proposed which is presented very high coefficient of determination.

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Relationship between surface roughness and chip morphology when turning hardened steel

Abidi Youcef

Production Engineering Archives

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2020

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Vol. 26, Iss. 3

92--98

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.

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Influence of the Trochoidal Tool Path Generation Method on the Milling Process Efficiency

Waszczuk Kamil

Advances in Science and Technology. Research Journal

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2020

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Vol. 14, no 3

199--203

EN

The article presents a comparison of three trochoidal paths: written by G-Code, generated using the overlays from the machine level, and generated using the CAD/CAM environment. The parameters determining the effectiveness of the process were: maximum achievable feed speed, surface roughness and waviness, cutting forces and cutting temperature when milling NC6 steel (50HRC) using a 10 mm cutter dimeter. The main measurement results include: an increase in the maximum feed speed value by almost 35% when using the A and C paths compared to the type B path and nearly a double increase in surface roughness when using the path generated using the CAD/CAM environment compared to the B path. The most important conclusions was that it is not always possible to machine with the recommended parameters by the tool manufacturer, especially when machining narrow grooves. It was proven that that the use of paths with the displacement described by arcs and straight lines as a trochoidal step over reduces the possibility of milling at high feed rate.

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Influence of the Trochoidal Tool Path on Quality Surface of Groove Walls

Waszczuk Kamil, Skowronek Hubert, Karolczak Paweł, Kowalski Maciej, Kołodziej Marek

Advances in Science and Technology. Research Journal

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2019

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Vol. 13, no 3

38--42

EN

The article presents the results of machining materials in hardened state. In the paper, different trochoidal tool paths are compared with each other and with the conventional milling. The results of measurements show the relationship between tool path, roughness and waviness of grooves wall. The paper also presents pictures of grooves which were made. These results provide comparative material useful in the choice of the best milling strategy to the cutting process.