Abstract
3D modeling of tool wear and optimization of hard turning have been performed in this study considering the tool geometry parameters, i.e., cutting edge and nose radii. Optimization is carried out using multiple objective and constraint, and it employs a meta-model that is developed using response surfaces based on radial basis functions. A 3D finite element model has been developed considering the tool geometry and is verified using force measurement during hard turning experiments on H-13. Chip formation simulations have been done using the coupled temperature displacement analysis based on explicit dynamics. The tool wear model is implemented using Usui’s model for adhesive wear. This model takes input from the steady-state chip formation analysis, and the contact nodes on the tool are repositioned according to the wear rate and time increment. The model is able to predict chip morphology, force components, tool wear, stress, and temperature distributions. The effects of cutting edge and nose radii on tool stresses, tool wear, and temperature have been discussed. For optimization search genetic algorithm, MOGA-II is selected which has been used to optimize tool temperature and material removal rate during hard turning. Optimize solutions suggest the selection of high to moderate cutting edge and nose radii, large feeds, and low to moderate cutting speeds.
Similar content being viewed by others
Data availability
The datasets generated and analyzed during the current study are available from the corresponding author on reason-able request.
References
Toenshoff HK (2019) Hard Material Cutting BT - CIRP Encyclopedia of Production Engineering. In: Chatti S, Laperrière L, Reinhart G, Tolio T (eds) Springer. Berlin Heidelberg, Berlin, Heidelberg, pp 855–863
Dawson TG (2002) Machining hardened steel with polycrystalline cubic boron nitride cutting tools. Georgia Institute of Technology. (PhD Thesis)
Bouacha K, Yallese MA, Mabrouki T, Rigal J-F (2010) Statistical analysis of surface roughness and cutting forces using response surface methodology in hard turning of AISI 52100 bearing steel with CBN tool. Int J Refract Met Hard Mater 28:349–361. https://doi.org/10.1016/j.ijrmhm.2009.11.011
Horng J-T, Liu N-M, Chiang K-T (2008) Investigating the machinability evaluation of Hadfield steel in the hard turning with Al2O3/TiC mixed ceramic tool based on the response surface methodology. J Mater Process Technol 208:532–541. https://doi.org/10.1016/j.jmatprotec.2008.01.018
Paiva AP, Ferreira JR, Balestrassi PP (2007) A multivariate hybrid approach applied to AISI 52100 hardened steel turning optimization. J Mater Process Technol 189:26–35. https://doi.org/10.1016/j.jmatprotec.2006.12.047
Özel T, Karpat Y (2005) Predictive modeling of surface roughness and tool wear in hard turning using regression and neural networks. Int J Mach Tools Manuf 45:467–479. https://doi.org/10.1016/j.ijmachtools.2004.09.007
Bouacha K, Yallese MA, Khamel S, Belhadi S (2014) Analysis and optimization of hard turning operation using cubic boron nitride tool. Int J Refract Met Hard Mater 45:160–178. https://doi.org/10.1016/j.ijrmhm.2014.04.014
Venkata Subbaiah K, Raju C, Suresh C (2020) Parametric analysis and optimization of hard turning at different levels of hardness using wiper ceramic insert. Measurement 158:107712. https://doi.org/10.1016/j.measurement.2020.107712
Mia M, Dey PR, Hossain MS, Arafat MT, Asaduzzaman M, Shoriat Ullah M, Tareq Zobaer SM (2018) Taguchi S/N based optimization of machining parameters for surface roughness, tool wear and material removal rate in hard turning under MQL cutting condition. Measurement 122:380–391. https://doi.org/10.1016/j.measurement.2018.02.016
Alok A, Das M (2019) Multi-objective optimization of cutting parameters during sustainable dry hard turning of AISI 52100 steel with newly develop HSN2-coated carbide insert. Measurement 133:288–302. https://doi.org/10.1016/j.measurement.2018.10.009
Sarjana SS, Bencheikh I, Nouari M, Ginting A (2020) Study on cutting performance of cermet tool in turning of hardened alloy steel. Int J Refract Met Hard Mater 91:105255. https://doi.org/10.1016/j.ijrmhm.2020.105255
Das A, Patel SK, Biswal BB, Sahoo N, Pradhan A (2020) Performance evaluation of various cutting fluids using MQL technique in hard turning of AISI 4340 alloy steel. Meas J Int Meas Confed 150:107079. https://doi.org/10.1016/j.measurement.2019.107079
Çetindağ HA, Çiçek A, Uçak N (2020) The effects of CryoMQL conditions on tool wear and surface integrity in hard turning of AISI 52100 bearing steel. J Manuf Process 56:463–473. https://doi.org/10.1016/j.jmapro.2020.05.015
Neslušan M, Uríček J, Mičietová A, Minárik P, Píška M, Čilliková M (2020) Decomposition of cutting forces with respect to chip segmentation and white layer thickness when hard turning 100Cr6. J Manuf Process 50:475–484. https://doi.org/10.1016/j.jmapro.2020.01.004
CAKIR MC, Sik IY (2005) Finite element analysis of cutting tools prior to fracture in hard turning operations. Mater Des 26:105–112. https://doi.org/10.1016/j.matdes.2004.05.018
Umbrello D, Ambrogio G, Filice L, Shivpuri R (2008) A hybrid finite element method–artificial neural network approach for predicting residual stresses and the optimal cutting conditions during hard turning of AISI 52100 bearing steel. Mater Des 29:873–883. https://doi.org/10.1016/j.matdes.2007.03.004
Jiang L, Wang D (2019) Finite-element-analysis of the effect of different wiper tool edge geometries during the hard turning of AISI 4340 steel. Simul Model Pract Theory 94:250–263. https://doi.org/10.1016/j.simpat.2019.03.006
Arfaoui S, Zemzemi F, Dakhli M, Tourki Z (2019) Optimization of hard turning process parameters using the response surface methodology and finite element simulations. Int J Adv Manuf Technol 103:1279–1290. https://doi.org/10.1007/s00170-019-03535-2
Magalhães FC, Ventura CEH, Abrão AM, Denkena B (2020) Experimental and numerical analysis of hard turning with multi-chamfered cutting edges. J Manuf Process 49:126–134. https://doi.org/10.1016/j.jmapro.2019.11.025
Ng EG, Aspinwall DK, Brazil D, Monaghan J (1999) Modelling of temperature and forces when orthogonally machining hardened steel. Int J Mach Tools Manuf 39:885–903. https://doi.org/10.1016/S0890-6955(98)00077-7
Umer U (2007) Experimental and finite element analyses for high speed machining of AISI H-13 hardened steel using advanced tool materials. Beijing Institute of Technology
Özel T (2003) Modeling of hard part machining: effect of insert edge preparation in CBN cutting tools. J Mater Process Technol 141:284–293. https://doi.org/10.1016/S0924-0136(03)00278-4
Takeyama H, Murata R (1963) Basic investigation of tool wear. J Eng Ind 85:33–37
Usui E, Shirakashi T, Kitagawa T (1978) Analytical Prediction of Three Dimensional Cutting Process—Part 3: Cutting Temperature and Crater Wear of Carbide Tool. ASME. J. Eng. Ind 100(2):236–243. https://doi.org/10.1115/1.3439415
Shaw MC (1977) Dimensional analysis for wear systems. Wear 43:263–266
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 209:5167–5177. https://doi.org/10.1016/j.jmatprotec.2009.03.002
ESTECO (2009) A simple multi-objective optimization problem. https://engineering.esteco.com/modefrontier/modefrontier-capabilities/
Zhou T, He L, Zou Z, du F, Wu J, Tian P (2020) Three-dimensional turning force prediction based on hybrid finite element and predictive machining theory considering edge radius and nose radius. J Manuf Process 58:1304–1317. https://doi.org/10.1016/j.jmapro.2020.09.034
Zhao T, Zhou JM, Bushlya V, Ståhl JE (2017) Effect of cutting edge radius on surface roughness and tool wear in hard turning of AISI 52100 steel. Int J Adv Manuf Technol 91:3611–3618. https://doi.org/10.1007/s00170-017-0065-z
Chou YK, Song H (2004) Tool nose radius effects on finish hard turning. J Mater Process Technol 148:259–268. https://doi.org/10.1016/j.jmatprotec.2003.10.029
Khlifi H, Abdellaoui L, Bouzid Sai W (2019) An equivalent geometry model for turning tool with nose and edge radii. Int J Adv Manuf Technol 103:4233–4251. https://doi.org/10.1007/s00170-019-03787-y
Acknowledgements
The authors are grateful to the Raytheon Chair for Systems Engineering for the funding.
Code availability
Not applicable.
Funding
This study received funding from the Raytheon Chair for Systems Engineering.
Author information
Authors and Affiliations
Contributions
Usama Umer: Data collection, analysis, original draft, and editing
Abdulrahman Al-Ahmari: Project administration, supervision, reviewing, and editing
Corresponding author
Ethics declarations
Ethical approval
The research does not involve human participants or animals and the authors warrant that the paper fulfils the ethical standards of the journal.
Consent to participate
It is confirmed that all the authors are aware and satisfied of the authorship order and correspondence of the paper.
Consent to publish
All the authors are satisfied that the last revised version of the paper is published without any change.
Conflict of interest
The authors declare no competing interests.
Additional information
Publisher’s note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Umer, U., Al-Ahmari, A. 3D modeling of tool wear and optimization in hard turning considering the effects of tool cutting edge and nose radii. Int J Adv Manuf Technol 118, 1919–1932 (2022). https://doi.org/10.1007/s00170-021-07998-0
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-021-07998-0