Skip to main content
SpringerLink
Log in

Effect of edge hone radius on chip formation and its microstructural characterization in hard milling of AISI H13 steel

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Chip formation as a key factor during the machining process can affect cutting stability and machined surface integrity, specifically the formation of saw-tooth chip. The saw-tooth chip formation with respect to edge hone radius during hard milling of AISI H13 steel (50 ± 1 HRC) was investigated in this paper involving chip morphology, metallurgical and mechanical property evolution, chemical composition distribution, and the mechanism of saw-tooth chip formation. The chip microstructural characterization was determined by means of optical microscopy, scanning electronic microscopy (SEM), a nano-tester, and X-ray diffraction (XRD). First, the effect of edge hone radius on chip morphology and evolution of chip color has been investigated. The results highlight that saw-tooth pitch decreases while the degree of segmentation is opposite with edge hone radius and the chip back surface color evolves gradually from purple to blue. Secondly, larger edge hone radius induces a thicker white layer generated on chip back surface and a higher value of nano-hardness identified inside an adiabatic shear band (ASB) as well as on chip back surface. In addition, the occurrence of phase transformation which occurs on chip back surface is observed which can be semi-quantified by the chip back surface color. Furthermore, the detected carbon content almost keep unvaried both in adiabatic shear band and on chip back surface, showing no impact on nano-hardness variation. Finally, it is indicated that the mechanism of saw-tooth chip formation in hard milling of AISI H13 steel is mainly attributed to adiabatic shearing accompanying with cyclic crack formation which facilitates the degree of segmentation. This research is a basic study for tool edge geometry preparation as well as controlling hard milling process.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Yan H, Hua J, Shivpuri R (2005) Numerical simulation of finish hard turning for AISI H13 die steel. Sci Technol Adv Mater 6(5):540–547

    Article  Google Scholar 

  2. Özel T (2009) Computational modelling of 3D turning: influence of edge micro-geometry on forces, stresses, friction and tool wear in PcBN tooling. J Mater Process Technol 209(11):5167–5177

    Article  Google Scholar 

  3. Klocke F, Kratz H (2005) Advanced tool edge geometry for high precision hard turning. Ann CIRP 54(1):47–50

    Article  Google Scholar 

  4. Boy M, Yaşar N, Çiftçi İ (2016) Experimental investigation and modelling of surface roughness and resultant cutting force in hard turning of AISI H13 steel. Mater Sci Eng 161(1):012039

    Google Scholar 

  5. Bosheh SS, Mativenga PT (2006) White layer formation in hard turning of H13 tool steel at high cutting speeds using CBN tooling. Int J Mach Tools Manuf 46(2):225–233

    Article  Google Scholar 

  6. Tang L, Yin J, Sun Y, Shen H, Gao C (2017) Chip formation mechanism in dry hard high-speed orthogonal turning of hardened AISI D2 tool steel with different hardness levels. Int J Adv Manuf Technol 9–12:1–16

    Google Scholar 

  7. Zhang S, Guo YB (2009) An experimental and analytical analysis on chip morphology, phase transformation, oxidation, and their relationships in finish hard milling. Int J Mach Tools Manuf 49(11):805–813

    Article  Google Scholar 

  8. Yang Q, Wu Y, Liu D, Chen L, Lou DY, Zhai ZS, Liu ZQ (2016) Characteristics of serrated chip formation in high-speed machining of metallic materials. Int J Adv Manuf Technol 86(5–8):1–6

    Google Scholar 

  9. Zang J, Zhao J, Li A, Pang J (2017) Serrated chip formation mechanism analysis for machining of titanium alloy Ti-6Al-4V based on thermal property. Int J Adv Manuf Technol 2:1–9

    Google Scholar 

  10. Du J, Liu Z (2012) Effect of cutting speed on surface integrity and chip morphology in high-speed machining of PM nickel-based superalloy FGH95. Int J Adv Manuf Technol 60(9–12):893–899

    Google Scholar 

  11. Duan CZ, Yu HY, Cai YJ, Li YY (2010) Finite element simulation and experiment of chip formation during high speed cutting of hardened steel. Appl Mech Mater 29-32:1838–1843

    Article  Google Scholar 

  12. Nakayama K (1977) On the formation of “saw-toothed chip” in metal cutting. Int J Jpn Soc Precis Eng 43(505):117–122

    Article  Google Scholar 

  13. Shawa MC, Vyasa A (1993) Chip formation in the machining of hardened steel. CIRP Ann Manuf Technol 42(1):29–33

    Article  Google Scholar 

  14. Komanduri R, Turkovich BFV (1981) New observations on the mechanism of chip formation when machining titanium alloys. Wear 69(2):179–188

    Article  Google Scholar 

  15. Recht RF (1985) A dynamic analysis of high-speed machining. Int J Eng Ind 107(4):309–315

    Article  Google Scholar 

  16. Wan ZP, Zhu YE, Liu HW, Tang Y (2012) Microstructure evolution of adiabatic shear bands and mechanisms of saw-tooth chip formation in machining Ti6Al4V. Mater Sci Eng A 531(531):155–163

    Article  Google Scholar 

  17. Kountanya R, Al-Zkeri I, Altan T (2009) Effect of tool edge geometry and cutting conditions on experimental and simulated chip morphology in orthogonal hard turning of 100Cr6 steel. J Mater Process Technol 209(11):5068–5076

    Article  Google Scholar 

  18. Zhang S, Li J, Zhu X, Lv H (2013) Saw-tooth chip formation and its effect on cutting force fluctuation in turning of Inconel 718. Int J Precis Eng Manuf 14(6):957–963

    Article  Google Scholar 

  19. Guo YB, Yen DW (2004) A FEM study on mechanisms of discontinuous chip formation in hard machining. J Mater Process Technol 155–156(6):1350–1356

    Article  Google Scholar 

  20. Pu CL, Zhu G, Yang S, Yue EB, Subramanian SV (2016) Effect of microstructure softening events on the chip morphology of AISI 1045 steel during high speed machining. Int J Adv Manuf Technol 82(9–12):2149–2155

    Article  Google Scholar 

  21. Woon KS, Rahman M (2010) The effect of tool edge radius on the chip formation behavior of tool-based micromachining. Int J Adv Manuf Technol 50(9–12):961–977

    Article  Google Scholar 

  22. Arısoy YM, Özel T (2015) Prediction of machining induced microstructure in Ti–6Al–4V alloy using 3-D FE-based simulations: effects of tool micro-geometry, coating and cutting conditions. J Mater Process Technol 220:1–26

    Article  Google Scholar 

  23. Lu S, Xie Q (2007) Study on adiabatic shear behaviour in orthogonal cutting of H13 steel. Springer, London

    Google Scholar 

  24. Cui T, Zhao HW, Liu C, Tian Y (2013) Microstructure evolution of Ti-6Al-4V alloy during high speed cutting: an investigation using finite element simulation. Appl Mech Mater 421:193–200

    Article  Google Scholar 

  25. Siemers C, Bäker M, Mukherji D, Rösler J (2003) Microstructure evolution in shear bands during the chip formation of Ti6Al4V. 10th World Conference on Titanium, At Hamburg, Germany, Volume: 1

  26. Duan CZ, Wang MJ, Yu HY (2012) Microstructure and formation mechanism of deterioration layer in hardened steel chips during high speed machining. Mater Sci Technol 20(3):127–131

    Google Scholar 

  27. Shi J, Liu CR (2006) On predicting chip morphology and phase transformation in hard machining. Int J Adv Manuf Technol 27(7–8):645–654

    Article  Google Scholar 

  28. Karpat Y, Özel T (2008) Mechanics of high speed cutting with curvilinear edge tools. Int J Mach Tools Manuf 48(2):195–208

    Article  Google Scholar 

  29. Ng EG, Aspinwall DK (2002) The effect of workpiece hardness and cutting speed on the machinability of AISI H13 hot work die steel when using PCBN tooling. J Manuf Sci Eng 124(3):588–594

    Article  Google Scholar 

  30. Venkatesh VC, Zhou DQ, Xue W, Quinto DT (1993) A study of chip surface characteristics during the machining of steel. CIRP Ann Manuf Technol 42(1):631–636

    Article  Google Scholar 

  31. Ning Y, Rahman M, Wong YS (2001) Investigation of chip formation in high speed end milling. J Mater Process Technol 113(1–3):360–367

    Article  Google Scholar 

  32. Griffiths BJ (1985) White layer formations at machined surfaces and their relationship to white layer formations at worn surfaces. J Tribol 107(2):165–171

    Article  Google Scholar 

  33. Han S, Melkote SN, Haluska MS, Watkins TR (2008) White layer formation due to phase transformation in orthogonal machining of AISI 1045 annealed steel. Mater Sci Eng A 488(1):195–204

    Article  Google Scholar 

  34. Barry J, Byrne G (2002) The mechanisms of chip formation in machining hardened steels. J Manuf Sci Eng 124(3):528–535

    Article  Google Scholar 

Download references

Funding

This work was supported by the National Natural Science Foundation of China (Grant No. 51575321 and No. 51175309) and the Taishan Scholars Program of Shandong Province.

Author information

Authors and Affiliations

  1. School of Mechanical Engineering, Shandong University, Jinan, 250061, China

    Binxun Li, Song Zhang, Zhenguo Yan & Jing Zhang

  2. Key Laboratory of High-Efficiency and Clean Mechanical Manufacture, Ministry of Education, Shandong University, Jinan, 250061, China

    Binxun Li, Song Zhang, Zhenguo Yan & Jing Zhang

Authors
  1. Binxun Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Song Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Zhenguo Yan
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Jing Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Song Zhang.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Li, B., Zhang, S., Yan, Z. et al. Effect of edge hone radius on chip formation and its microstructural characterization in hard milling of AISI H13 steel. Int J Adv Manuf Technol 97, 305–318 (2018). https://doi.org/10.1007/s00170-018-1933-x

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-018-1933-x

Keywords

Search

Navigation