Advertisement

Analysis of tool wear and surface finish in hard turning

  • T. Tamizharasan
  • T. Selvaraj
  • A. Noorul HaqEmail author
Original Article

Abstract

Hard turning is a profitable alternative to finish grinding. The ultimate aim of hard turning is to remove work piece material in a single cut rather than a lengthy grinding operation in order to reduce processing time, production cost, surface roughness, and setup time, and to remain competitive. In recent years, interrupted hard turning, which is the process of turning hardened parts with areas of interrupted surfaces, has also been encouraged. The process of hard turning offers many potential benefits compared to the conventional grinding operation. Additionally, tool wear, tool life, quality of surface turned, and amount of material removed are also predicted. In this analysis, 18 different machining conditions, with three different grades of polycrystalline cubic boron nitride (PCBN), cutting tool are considered. This paper describes the various characteristics in terms of component quality, tool life, tool wear, effects of individual parameters on tool life and material removal, and economics of operation. The newer solution, a hard turning operation, is performed on a lathe. In this study, the PCBN tool inserts are used with a WIDAX PT GNR 2525 M16 tool holder. The hardened material selected for hard turning is commercially available engine crank pin material.

Keywords

Hard turning DOE Material removal rate  Signal-to-noise ratio Tool life Validation 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

References

  1. 1.
    Pavel R et al (2001) Surface quality and tool wear in interrupted hard turning of 1137 steel shafts. Dana company, MIME Department, Advanced Technoplogy Resource Group, Technical Resource Park, Ottawa Lake, MI 49267, pp 1–6Google Scholar
  2. 2.
    Chou YK et al (2002) Experimental investigation on CBN turning of hardened AISI 52100 steel. J Mater Process Technol 124:274–283CrossRefGoogle Scholar
  3. 3.
    Konig W et al (1993) Turning versus grinding–A comparison of surface integrity aspects and attainable accuracies. Ann CIRP 42:39–43Google Scholar
  4. 4.
    Abrao AM, Aspinwall DK (1996) The surface integrity of turned and ground hardened bearing steel. Wear 196:279–284CrossRefGoogle Scholar
  5. 5.
    Saroka DP (2000) Hard turning and machine tools. Brochure of Elmira, New YorkGoogle Scholar
  6. 6.
    Griffiths BJ (1987) Mechanism of white layer generation with reference to machining processes and deformation processes. ASME J Tribology 42:145–152Google Scholar
  7. 7.
    Dawson TG, Kurfees TR (2000) An investigation of tool wear and surface quality in hard turning. In: Transactions of 28th annual North American Manufacturing Research Institution of SME, University of Kentucky, Lexington, May 24–26, pp 215–220Google Scholar
  8. 8.
    Tonshoff HK, Wobker HG, Brandt D (1995) Hard turning influence on the workpiece properties. Trans NAMRI/SME 23:215–220Google Scholar
  9. 9.
    Zhao H, Barber GC, Zou Q (2002) A study of flank wear in orthogonal cutting with internal cooling. Wear 253:957–962CrossRefGoogle Scholar
  10. 10.
    Feng C-X (2001) An experimental study of the impact of turning parameters on surface roughness. In: Proceedings of the International Conference on Industrial Engineering Research, Bradley university, USA, Institute of Industrial Engineers, Norcross, GA, March 27–28, pp 1–11Google Scholar
  11. 11.
    Chou Y, Evans CJ (1996) Microstructural effects in precision hard turning. ASME J Manuf 4:237–242Google Scholar
  12. 12.
    Takastu S, Shimoda H, Otani K (1983) Effects of CBN content on the performance of PCBN tools. Int J Refractory Hard Mater 12:175–178Google Scholar
  13. 13.
    Konig W, Komanduri R, Tonstoff HK, Ackershott G (1984) Machining of hard materials. Ann CIRP 33(2):417–427Google Scholar
  14. 14.
    Negishi H, Aoki A, Sata T (1980) Study of tool failure of carbide tools in interrupted cutting. Ann CIRP 29:57–60Google Scholar
  15. 15.
    Dewes RC, Aspinwall DK (1996) The use of high speed machining for the manufacture of hardened steel dies. Trans NAMRI/SME 24:21–26Google Scholar
  16. 16.
    Chou YK, Chris J, Evans (1999) Cubic boron nitride tool wear in interrupted hard turning. Wear 225:234–245CrossRefGoogle Scholar
  17. 17.
    Bhattacharyya A (2000) Metal cutting – theory and practice. New Central Book Agencies Private Limited, Calcutta, IndiaGoogle Scholar
  18. 18.
    Huddle D (2001) New hard turning tools and techniques offer a cost effective alternative to grinding. Tooling Prod Magazine 80:96–103. Advanced Materials Carbohy, Inc., 6001 cochran head, Suite 104 Solon, Nelson Publishers, July 1997Google Scholar
  19. 19.
    Huang Y, Liang SY, George W (2003) Cutting forces modeling considering the effects of tool thermal properties applicable to CBN hard turning. Int J Mach Tool Manuf 3:1–15Google Scholar
  20. 20.
    Moylan SP, Kompella S, Chandrasekar S, Farris TN (2003) A new approach for studying mechanical properties of thin surface layers affected by manufacturing processes. ASME J Manuf Sci Eng 125:310–315CrossRefGoogle Scholar
  21. 21.
    Brinksmeier E, Brockhiff T (1999) White layers in machining steels. In: Proceedings of Second International Conference on high Speed machining. Recherche publications, Darmstadt, Germany, March 10–11, pp 7–13Google Scholar
  22. 22.
    Konig W, Klinger M, Link R (1990) Machining hard materials with geometrically defined cutting edges. Ann CIRP 39(1):61–64Google Scholar
  23. 23.
    Bendell T (1998) Taguchi methods, In: Proceedings of the 1998 European conference on Taguchi Method. Elsevier, AmsterdamGoogle Scholar
  24. 24.
    Ghani JA, Chaudhoury IA, Hassan HH (2004) Application of Taguchi method in the optimization of end milling parameters. J Mater Process Technol 145:84-92CrossRefGoogle Scholar
  25. 25.
    Tekiner Z (2004) An experimental study on the examination of springback of sheet metals with several thicknesses and properties in bending dies. J Mater Process Technol 145:109–117CrossRefGoogle Scholar
  26. 26.
    Liu CR, Mittal S (1998) Optimal prestressed surface of a component by super finish hard turning for maximum fatigue life in rolling contact. Wear 219:128–140CrossRefGoogle Scholar
  27. 27.
    Kopac J, Bahor M, Sokovic M (2002) Optimal machining parameters for achieving the desired surface roughness in fine turning of cold preformed steel work pieces. Int J Mach Tools Manuf 42:707–796CrossRefGoogle Scholar
  28. 28.
    Tonshoff HK, Wobker HG, Brandt D (1996) Tool wear and surface integrity in hard turning. Prod Eng 3(1):19–24Google Scholar
  29. 29.
    Auschner W (1997) Stone super finishing of hard turned surfaces. Machining Technol Association SME 8(3):1–05Google Scholar
  30. 30.
    Thiele JD, Melkote SN (1999) Effects of edge geometry and workpiece hardness on surface generation in finish machining of AISI 52100 steel. J Mater Process Technol 94:216–226CrossRefGoogle Scholar
  31. 31.
    Matsumoto Y, Narutaki N (1996) Tool-workpiece interaction in precision hard turning. Riner Points 8(4):14–16Google Scholar
  32. 32.
    Thiele JD (1998) An investigation of surface generation mechanisms for finish hard turning of AISI52100 steel. Master’s Thesis, Georgia Institute of TechnologyGoogle Scholar
  33. 33.
    Matsumoto Y, Barash MM (1987) Review on cutting technology of hard materials. In: Proceedings of Sixth International Conference on Production Engineering, Japan, pp 116–122Google Scholar
  34. 34.
    Ekstedt T (1987) Challenge of hard turning. Carbide Tool J 19:21–24Google Scholar
  35. 35.
    Bossom PK (1990) Finish machining of hard ferrous workpieces. Ind Diamond Rev 50(540):228–232Google Scholar
  36. 36.
    Barry J, Byrne G (2001) Cutting tool wear in the machining of hardened steels, part II. Wear 247:139–151CrossRefGoogle Scholar
  37. 37.
    Chen JC, Huang LH, Lan AX, Lee S (1999) Analysis of an effective sensing location for an in-process surface recognition system in turning operations. J Ind Technol 15(3):1–6zbMATHGoogle Scholar
  38. 38.
    Davies MA, Chou YK, Evans CJ (1996) Onchip morphology, tool wear and cutting mechanics in finish hard turning. Ann CIRP 45(1):77–82CrossRefGoogle Scholar

Copyright information

© Springer-Verlag 2005

Authors and Affiliations

  1. 1.Department of Production EngineeringNational Institute of TechnologyTiruchirappalliIndia

Personalised recommendations