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Effect of edge hone radius on plowing-induced plastic deformation in hard milling: analytical modeling and experimental validation

  • Binxun Li
  • Song ZhangEmail author
  • Yujie Fang
ORIGINAL ARTICLE
  • 12 Downloads

Abstract

Microstructure alteration in the machined surface layer has a major impact on the functional performances of machined metal parts. Plastic deformation induced by high intensity of localized thermo-mechanical loads is more prominent in hard machining. Edge hone is recognized as a method to diminish tool wear, prevent chipping, and therefore guarantee the surface quality in hard machining. However, the plowing effect resulted from edge hone induces severe friction and deep plastic deformation. In this paper, a thermo-mechanically coupled prediction model was developed to estimate the depth of plastic deformation considering the plowing effect. The depth of plastic deformation induced by machining with different edge hone radii could be effectively measured with the proposed prediction model. Hard milling experiments were conducted on AISI H13 steel to verify the proposed model. A quantitative comparison indicates that there is a good agreement between the experimental results and the predicted results with the relative errors ranging from 4.14 to 14.28 %. This research provides useful guidance for edge hone radius selection and guaranteed surface integrity.

Keywords

Analytical model Plowing effect Thermo-mechanical loads Plastic deformation Hard milling AISI H13 steel 

Nomenclature

Fi

Measured cutting force in i-direction (N)

N, F

Shear force and normal force (N)

Fcs

Cutting force component (N)

Fts

Thrust force component (N)

Fcp, Ftp

Cutting and thrust forces induced by plowing (N)

Fs

Resultant force in the x-y plane (N)

φ, β

Shear angle and friction angle (°)

θ

Tool rotation angle (°)

ts, tr

Heating time by the shear plane heat source and hone rubbing heat source

qs

Primary heat source intensity (W/mm2)

qr

Rubbing heat source intensity (W/mm2)

λ

Thermal conductivity of workpiece material (W/mm °C)

λt

Thermal conductivity of tool material (W/mm °C)

v

Moving velocity of the primary heat source (mm/s)

a

Thermal diffusivity of workpiece (mm2/s)

K0

Modified Bessel function of the second kind of order zero

a0, t0

Uncut chip thickness (mm), depth of plowing layer

L

Length of the primary heat source (mm)

R

Radius of circular fan

ζ

Fan field angle

η

Angle between slip line and bottom surface of build-up region

δ, α

Prow angle, plowing angle

l0

Length of hone associated with rubbing (mm)

w

Axial depth of cut (mm)

γ

Rake angle (°)

Tm

Workpiece temperature rise due to the primary heat source (°C)

Tr

Workpiece temperature rise due to rubbing heat source (°C)

k

Coefficient of cutting heat conducting into workpiece

ρ

Density of workpiece material (kg/mm3)

ρt

Density of tool material (kg/mm3)

c

Specific heat capacity of workpiece material (J/kg °C)

ct

Specific heat capacity of tool material (J/kg °C)

σm

Mechanical stress (MPa)

σt

Thermal stress (MPa)

Ew

Elastic modulus of workpiece material (GPa)

p(s), q(s)

Normal force distribution (N); tangential force distribution (N)

αw

Thermal expansion coefficient of workpiece

ff

Maximum value of cutting force in feed direction (N)

fv

Maximum value of cutting force in speed direction (N)

υ

Poisson’s rate of workpiece material

σeq

Equivalent stress (MPa)

σys

Yield strength of workpiece material (MPa);

Notes

Funding information

This work was supported by the National Natural Science Foundation of China (Grants No. 51975333 and No. 51575321) and Taishan Scholar Project of Shandong Province (No. ts201712002).

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Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2019

Authors and Affiliations

  1. 1.Key Laboratory of High Efficiency and Clean Mechanical Manufacture of MOE, School of Mechanical EngineeringShandong UniversityJinanPeople’s Republic of China
  2. 2.Key National Demonstration Center for Experimental Mechanical Engineering EducationShandong UniversityJinanPeople’s Republic of China

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