Abstract
This chapter presents basic knowledge on the special kind of the machining process in which a workpiece material hardened to 45–70 HRC hardness or more is machined with mixed ceramic or CBN tools. An extended comparison with finish grinding, as well with other abrasive finishing processes, is carried out. Specific cutting characteristics, including cutting forces, chip formation mechanisms and tool wear modes with relevant interface temperatures are discussed in terms of process conditions. Currently developing finite element (FE) and analytical modelling is overviewed. A complete characterization of surface integrity including geometrical features of hard-machined surfaces, along with specific microstructural alterations and process-induced residual stresses, is provided. Finally, the state of the art of hard cutting technology is addressed for many cutting operations to show how manufacturing chains can be effectively utilized and optimized in practice.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
Preview
Unable to display preview. Download preview PDF.
References
Byrne G, Dornfeld D, Denkena B (2003) Advancing cutting technology. Ann CIRP 52/2, 483–507.
Erdel BP (2003) High-Speed Machining. SME, Dearborn.
Klocke F, Brinksmeier E, Weinert K (2005) Capability profile of hard cutting and grinding processes. Ann CIRP 54/2, 557–580.
Eredel BP (1998) New dimensions in manufacturing, Hanser Gardner, Cincinnati
Dewes CR, Aspinwall DK (1996) The use of high speed machining for the manufacture of hardened steel dies. Trans NAMRI/SME 24, 21–26.
www.coromant.sandvik.com; www.secotools.com; www.mitsubishicarbide.com, www.yasda.com, www.hardinge.com (accessed 2007).
Klocke F, Brinksmeier E, Weinert K (2005) Capability profile of hard cutting and grinding processes. Ann CIRP 54/2, 557–580.
Mushardt H, Manger P (2001) Komplettbearbeitung mit Hartdrehen und Schleifen. Werkstatt und Betrieb. 134/1–2, 37–40.
Beyer R (2002) Hard turning and grinding of HSK tool holders, MAV, No. 10, www.hskworld.com.
Köpfer Ch, When does hard turn/grind make sense?, www.mmsonline.com/articles/040203/html (accessed 2007).
Tönshoff HK, Arendt C, Amor R Ben (2000) Cutting of hardened steel. Ann CIRP 49/2, 547–566.
Barry J, Byrne G (2002) The mechanisms of chip formation in machining hardened steels. Trans ASME J Manuf Sci Eng 124, 528–535.
Davies MA, Burns TJ, Evans CJ (1997) On the dynamics of chip formation in machining hard metals. Ann CIRP 46/1, 25–30.
Davies MA, Chou CJ, Evans CJ (1996) On chip morphology, tool wear and cutting mechanics in finish hard turning. Ann CIRP 45/1, 77–82.
Poulachon G, Moisan A, Jawahir IS (2001) On modelling the influence of thermo-mechanical behavior in chip formation during hard turning of 100Cr6 bearing steel. Annals CIRP 50/1, 31–36.
Shaw MC, A Vyas (1993) Chip formation in the machining of hardened steel, Ann CIRP 42/1, 29–33.
König W, Klocke F (1997) Fertigungsverfahren 1. Drehen, Fräsen, Bohren, Springer, Berlin.
König W, Berktold A, Koch KF (1993) Turning versus grinding-a comparison of surface integrity aspects and attainable accuracies. Ann CIRP 42/1, 39–43.
Kishawy HA, Elbestawi MA (1999) Effects of process parameters on material side flow during hard turning. Int J Mach Tools Manuf 39, 1017–1030.
Ueda T Huda M Al, Yamada K, Nakayama K (1999) Temperature measurement of CBN tool in turning of high hardness steel. Ann CIRP, 48/1, 63–66.
Wang JY, Liu CR (1999) The effect of tool flank wear on the heat transfer, thermal damage and cutting mechanics in finish hard turning. Ann CIRP, 48/1, 53–58.
Dewes RC, Ng E, Chua KS, Newton PG, Aspinwall DK (1999) Temperature measurement when high speed machining hardened moul/die steel. J Mater Process Technol 92–93, 293–301.
Chou YK, Song H (2004) Tool nose radius effects on finish hard turning. J Mater Process Technol 148, 259–268.
Grzesik W, Krol S, Wanat T, Zalisz Z (2007) Wear behaviour of mixed ceramic tools and deterioration of surface finish in the machining of a hardened alloy steel, Proceedings of the 4th International Conference on Advances in Production Engineering, Warsaw, Poland, 267–274.
Chou YK, Evans ChJ (1997) Tool wear mechanism in continuous cutting of hardened tool steels. Wear 212, 59–65.
Mamalis AG, Branis AS, Manolakos DE (2002) Modelling of precision hard cutting using implicit finite element method. J Mater Proces Technol 123, 464–475.
Huang Y, Liang SY (2003) Cutting forces modelling considering the effect of tool thermal property-application to CBN hard turning. Int J Mach Tools Manuf 43, 307–475.
Wen Q, Guo YB, Todd BA (2006) An adaptive FEA method to predict surface quality in hard machining. J Mater Process Technol 173, 21–28.
Guo YB, Yen DW (2004) Hard turning versus grinding-the effect of process-induced residual stress on rolling contact. Wear 256, 393–399.
Özel T, Karpat Y, Figueira L, Davim JP (2007) Modelling of surface finish and tool flank wear in turning of AISI D2 steel with ceramic wiper inserts. J Mater Process Technol 189, 192–198.
Umbrello D, Ambrogio G, Filice L, Shivpuri R (2007) An ANN approach for predicting subsurface residual stresses and the desired cutting conditions during hard turning. J Mater Process Technol 189, 143–152.
Ng EG, Aspinwall DK (2002) Modelling of hard part machining. J Mater Process Technol 127, 222–229.
Grzesik W, Wanat T (2006) Surface finish generated in hard turning of quenched alloy steel parts using conventional and wiper ceramic inserts. Int J Mach Tools Manuf 46, 1988–1995.
Grzesik W, Wanat T (2005) Hard turning of quenched alloy steel parts using conventional and wiper ceramic inserts. Trans NAMRI/SME 33, 9–16.
Rech J, Moisan A (2003) Surface integrity in finish hard turning of case-hardened steels. Int J Mach Tools Manuf 43, 543–550.
Lima JG, Avila RF, Abrao AM, Faustino M, Davim JP (2005) Hard turning: AISI 4340 high strength alloy steel and AISI D2 cold work tool steel. J Mater Process Technol 169, 388–395.
Hashimoto F, Melkote SN, Singh R, Kalil R (2007) Effect of finishing methods in surface characteristics and performance of precision components in rolling/sliding contact, Proceedings of the 10th CIRP International Workshop on Modeling of Machining Operations, Reggio Calabria, Italy, 21–26.
Dahlman P, Gunnenberg F, Jacobson M (2004) The influence of rake angle, cutting feed and cutting depth on residual stresses in hard turning. J Mater Process Technol 147, 181–184.
Liu M, Takagi JI, Tsukuda A (2004) Effect of tool nose radius and tool wear on residual stress distribution in hard turning of bearing steel. J Mater Process Technol 150, 234–241.
Zhou JM, Anderson M, Ståhl JE (2004) Identification of cutting errors in precision machining hard turning process. J Mater Process Technol 153–154, 746–750.
Chou YK, Evans ChJ (1998) Process effects on white layer formation in hard turning. Trans NAMRI/SME 26, 117–122.
Hashimoto F, Guo YB, Warren AW (2006) Surface integrity difference between hard turned and ground surfaces and its impact on fatigue life. Ann CIRP 55/1, 81–84.
Hard broaching, www.faessler-ag.ch (accessed 2006).
Huddle D (2002) Plunge turning can be a cost-effective grinding alternative. Manuf Eng 128/4, 76–81. CIRP Ann 55/1 (2006) pp. 81–84.
Mickelson D (2007) Guide to Hard Milling & High Speed Machining. Industrial, New York, NY.
Kress D (2001) Erfolge furs Hartreiben und Hartfräsen. Werkstatt und Betrieb 133/1–2, 64–65.
Klocke F, Kratz H (2005) Advanced tool edge geometry for high precision hard turning. Annals CIRP 54/1, 47–50.
Author information
Authors and Affiliations
Rights and permissions
Copyright information
© 2008 Springer London
About this chapter
Cite this chapter
Grzesik, W. (2008). Machining of Hard Materials. In: Machining. Springer, London. https://doi.org/10.1007/978-1-84800-213-5_4
Download citation
DOI: https://doi.org/10.1007/978-1-84800-213-5_4
Publisher Name: Springer, London
Print ISBN: 978-1-84800-212-8
Online ISBN: 978-1-84800-213-5
eBook Packages: EngineeringEngineering (R0)