Skip to main content
SpringerLink
Log in

Cutting performance and machining economy of the hard cutting tools in clean cutting of hardened H13 steel

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

Abstract

The problems of tool wear and machining economy are prominent in hard cutting process. Clean cutting technology can effectively improve the cutting environment. The cutting performance of coated tools and PCBN tools is investigated in clean hard cutting of H13 steel (55 ± 1 HRC) under dry, cold air, and cryogenic liquid nitrogen conditions. The machining economics are also analyzed to investigate the feasibility of improving tool life through clean cutting technology. From the perspective of machining economy, the machining cost of cold air cutting is lower than that of dry cutting and liquid nitrogen cutting. The coated tool is suitable for cutting under cryogenic liquid nitrogen condition. Compared with dry cutting, the coated tool life is increased by 55.6% at cryogenic liquid nitrogen condition. PCBN tools are prone to chipping at cryogenic temperature, resulting in early failure. PCBN tools achieve the longest tool life in cold air cutting.

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

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12

Similar content being viewed by others

Data availability

All data generated or analyzed during this study are included in the present article.

Abbreviations

PCBN:

Polycrystalline cubic boron nitride

VB max :

Maximum flank wear width

f z :

Feed per tooth (mm/z)

a e :

Width of cutting (mm)

EDS:

Energy spectrum analyzer

Ka:

Sum of unit time (min) machine tool use cost, labor cost, and factory management cost

K c :

Unit time (min) cooling cost

T :

Tool life (min)

t m :

Actual machining time (min)

C machining :

Machining cost

C cooling :

Cooling cost

W t :

Ratio of machine tool cost to the product of machine tool annual working time and depreciation cycle

β :

Ratio of machine tool power consumption fee, maintenance fee, installation fee to machine tool depreciation fee

D:

Milling cutter diameter

UNEP:

United Nations Environment Programmer

v c :

Cutting speed (m/min)

a p :

Depth of cutting (mm)

SEM:

Scanning electron microscope

C total :

Cost of producing a single product

K T :

Tool depreciation fee

t a :

Auxiliary time

t c :

Tool change time (min)

C ancillary :

Auxiliary cost

C tool change :

Tool change cost

W o :

Wage rate of workers

α :

Ratio of workers’ welfare and non-productive workers “wages to workers” wages

MRR :

Material removal rate (mm3/min)

z :

Cutter tooth number

References

  1. Kshitij G, Khanna N, Yıldırım ÇV, Dağlı S, Sarıkaya M (2022) Resource conservation and sustainable development in the metal cutting industry within the framework of the green economy concept: an overview and case study. Sustain Mater Technol 34:e00507. https://doi.org/10.1016/j.susmat.2022.e00507

    Article  CAS  Google Scholar 

  2. Krolczyk GM, Maruda RW, Krolczyk JB, Wojciechowski S, Mia M, Nieslony P, Budzik G (2019) Ecological trends in machining as a key factor in sustainable production–a review. J Clean Prod 218:601–615. https://doi.org/10.1016/j.jclepro.2019.02.017

    Article  CAS  Google Scholar 

  3. Cui X, Sun N, Guo J, Ma J, Ming P (2023) Performance of multi-bionic hierarchical texture in green intermittent cutting. Int J Mech Sci 247:108203. https://doi.org/10.1016/j.ijmecsci.2023.108203

    Article  Google Scholar 

  4. Cui X, Duan S, Guo J, Ming P (2022) Bionic multifunctional surface microstructure for efficient improvement of tool performance in green interrupted hard cutting. J Mater Process Technol 305:117587. https://doi.org/10.1016/j.jmatprotec.2022.117587

    Article  CAS  Google Scholar 

  5. Gupta MK, Niesłony P, Korkmaz ME, Kuntoğlu M, Królczyk GM, Günay M, Sarikaya M (2023) Comparison of tool wear, surface morphology, specific cutting energy and cutting temperature in machining of titanium alloys under hybrid and green cooling strategies. Int J Precis Eng Manuf-Green Technol:1–14. https://doi.org/10.1007/s40684-023-00512-9

  6. Yağmur S (2021) The effects of cooling applications on tool life, surface quality, cutting forces, and cutting zone temperature in turning of Ni-based Inconel 625. Int J Adv Manuf Technol 116(3-4):821–833. https://doi.org/10.1007/s00170-021-07489-2

    Article  Google Scholar 

  7. König W, Komanduri R, Toenshoff HK, Ackershott G (1984) Mach Hard Mater CIRP Ann 33(2):417–427. https://doi.org/10.1016/S0007-8506(16)30164-0

    Article  Google Scholar 

  8. Hassan S, Khan SA, Naveed R, Saleem MQ, Mufti NA, Farooq MU (2023) Investigation on tool wear mechanisms and machining tribology of hardened DC53 steel through modified CBN tooling geometry in hard turning. Int J Adv Manuf Technol 1-18. https://doi.org/10.1007/s00170-023-11528-5

  9. Khatai S, Kumar R, Sahoo AK, Panda A (2022) Investigation on tool wear and chip morphology in hard turning of EN 31 steel using AlTiN-PVD coated carbide cutting tool. Mater Today: Proc 59:1810–1816. https://doi.org/10.1016/j.matpr.2022.04.387

    Article  CAS  Google Scholar 

  10. Hussain G, Alkahtani M, Alsultan M, Buhl J, Gupta MK (2022) Chip formation, cutting temperature and forces measurements in hard turning of Gcr15 under the influence of PcBN chamfering parameters. Measurement 204:112130. https://doi.org/10.1016/j.measurement.2022.112130

    Article  Google Scholar 

  11. Zhang Q, Zhang S, Li J (2017) Three dimensional finite element simulation of cutting forces and cutting temperature in hard milling of AISI H13 steel. Proc Manuf 10:37–47. https://doi.org/10.1016/j.promfg.2017.07.018

    Article  Google Scholar 

  12. Liew PJ, Shaaroni A, Sidik NAC, Yan J (2017) An overview of current status of cutting fluids and cooling techniques of turning hard steel. Int J Heat Mass Transf 114:380–394. https://doi.org/10.1016/j.jmapro.2020.06.010

    Article  Google Scholar 

  13. Bakar HA, Ghani JA, Haron CC, Ghazali MJ, Kasim MS, Al-Zubaidi S, Jouini N (2023) Wear mechanisms of solid carbide cutting tools in dry and cryogenic machining of AISI H13 steel with varying cutting-edge radius. Wear 523:204758. https://doi.org/10.1016/j.wear.2023.204758

    Article  CAS  Google Scholar 

  14. Ravi S, Gurusamy P (2020) Experimental investigation of cryogenic cooling on cutting force, surface roughness and tool wear in end milling of hardened AISI D3 steel using uncoated tool. Mater Today: Proc 33:3314–3318. https://doi.org/10.1016/j.matpr.2020.04.741

    Article  CAS  Google Scholar 

  15. Kumar S, Gandotra S (2021) Effect of cooling air on machining performance during hard turning. Mater Today: Proc 38:2213–2216. https://doi.org/10.1016/j.matpr.2020.06.263

    Article  CAS  Google Scholar 

  16. Agrawal C, Khanna N, Pruncu CI, Singla AK, Gupta MK (2020) Tool wear progression and its effects on energy consumption and surface roughness in cryogenic assisted turning of Ti-6Al-4V. Int J Adv Manuf Technol 111:1319–1331. https://doi.org/10.1007/s00170-020-06140-w

    Article  Google Scholar 

  17. Akeel AM, Kumar R, Chandrasekhar P, Panda A, Sahoo AK (2022) Hard to cut metal alloys machining: aspects of cooling strategies, cutting tools and simulations. Mater Today: Proc 62:3208–3212. https://doi.org/10.1016/j.matpr.2022.04.053

    Article  Google Scholar 

  18. Schalk N, Tkadletz M, Mitterer C (2022) Hard coatings for cutting applications: physical vs. chemical vapor deposition and future challenges for the coatings community. Surf Coat Technol 429:127949. https://doi.org/10.1016/j.surfcoat.2021.127949

    Article  CAS  Google Scholar 

  19. 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

    Article  ADS  Google Scholar 

  20. Bag R, Panda A, Sahoo AK, Kumar R (2020) Cutting tools characteristics and coating depositions for hard part turning of AISI 4340 martensitic steel: a review study. Mater Today: Proc 26:2073–2078. https://doi.org/10.1016/j.matpr.2020.02.448

    Article  CAS  Google Scholar 

  21. Zhao J, Liu Z (2020) Influences of coating thickness on cutting temperature for dry hard turning Inconel 718 with PVD TiAlN coated carbide tools in initial tool wear stage. J Manuf Process 56:1155–1165. https://doi.org/10.1016/j.jmapro.2020.06.010

    Article  Google Scholar 

  22. Liu C, Zhang Z, Yang G, Zhou A, Wang G, Qin S, Wang A, Wang W, Zhang X (2022) Finite element analysis and wear mechanism of B4C–TiB2 ceramic tools in turning AISI 4340 workpieces. Ceram Int 48(4):5459–5467. https://doi.org/10.1016/j.ceramint.2021.11.090

    Article  CAS  Google Scholar 

  23. Srithar A, Palanikumar K, Durgaprasad B (2019) Experimental investigation and surface roughness analysis on hard turning of AISI D2 steel using polycrystalline cubic boron nitride (PCBN). Mater Today: Proc 16:1061–1066. https://doi.org/10.1016/j.matpr.2019.05.196

    Article  CAS  Google Scholar 

  24. Zhang F, Duan CZ, Wang MJ, Sun W (2018) White and dark layer formation mechanism in hard cutting of AISI52100 steel. J Manuf Process 32:878–887. https://doi.org/10.1016/j.jmapro.2018.04.011

    Article  Google Scholar 

  25. Nayak M, Sehgal R, Kumar R (2021) Investigating machinability of AISI D6 tool steel using CBN tools during hard turning. Mater Today: Proc 47:3960–3965. https://doi.org/10.1016/j.matpr.2021.04.020

    Article  CAS  Google Scholar 

  26. Shi B, Elsayed A, Damir A, Attia H, M'Saoubi R (2019) A hybrid modeling approach for characterization and simulation of cryogenic machining of Ti–6Al–4V alloy. J Manuf Sci Eng 141(2):021021. https://doi.org/10.1115/1.4042307

    Article  Google Scholar 

  27. Agrawal C, Wadhwa J, Pitroda A, Pruncu CI, Sarikaya M, Khanna N (2021) Comprehensive analysis of tool wear, tool life, surface roughness, costing and carbon emissions in turning Ti–6Al–4V titanium alloy: cryogenic versus wet machining. Tribol Int 153:106597. https://doi.org/10.1016/j.triboint.2020.106597

    Article  CAS  Google Scholar 

  28. Agarwal G, Khare MK (2021) Multiobjective optimisation of cutting parameters in machining–a sustainable approach. Mater Today: Proc 46:5535–5543. https://doi.org/10.1016/j.matpr.2020.09.272

    Article  Google Scholar 

  29. Prado MT, Pereira A, Pérez JA, Mathia TG (2017) Methodology for tool wear analysis by a simple procedure during milling of AISI H13 and its impact on surface morphology. Proc Manuf 13:348–355. https://doi.org/10.1016/j.promfg.2017.09.090

    Article  Google Scholar 

  30. Yıldırım ÇV, Kıvak T, Sarıkaya M, Şirin Ş (2020) Evaluation of tool wear, surface roughness/topography and chip morphology when machining of Ni-based alloy 625 under MQL, cryogenic cooling and CryoMQL. J Mater Res Technol 9(2):2079–2092. https://doi.org/10.1016/j.jmrt.2019.12.069

    Article  CAS  Google Scholar 

  31. Ravi S, Kumar MP (2011) Experimental investigations on cryogenic cooling by liquid nitrogen in the end milling of hardened steel. Cryogenics 51(9):509–515. https://doi.org/10.1016/j.cryogenics.2011.06.006

    Article  CAS  ADS  Google Scholar 

  32. Uysal A, Jawahir IS (2021) Analysis of slip-line model for serrated chip formation in orthogonal machining of AISI 304 stainless steel under various cooling/lubricating conditions. J Manuf Process 67:447–460. https://doi.org/10.1016/j.jmapro.2021.05.009

    Article  Google Scholar 

  33. Hariprasad B, Selvakumar SJ, Raj DS (2022) Effect of cutting edge radius on end milling Ti-6Al-4V under minimum quantity cooling lubrication–chip morphology and surface integrity study. Wear 498:204307. https://doi.org/10.1016/j.wear.2022.204307

    Article  CAS  Google Scholar 

  34. Bagaber SA, Yusoff AR (2018) Sustainable optimization of dry turning of stainless steel based on energy consumption and machining cost. Proc CIRP 77:397–400. https://doi.org/10.1016/j.procir.2018.08.300

    Article  Google Scholar 

  35. Narita H (2013) A study of automatic determination of cutting conditions to minimize machining cost. Proc CIRP 7:217–221. https://doi.org/10.1016/j.procir.2013.05.037

    Article  Google Scholar 

Download references

Funding

This work is supported by the Innovation Ability Promotion Project of Sci-Tech SMEs in Shandong Province [No. 2021TSGC1433], and the Natural Science Foundation of Shandong Province [No. ZR2020ME156].

Author information

Authors and Affiliations

  1. School of Mechanical Engineering, Shandong University of Technology, 266 West Xincun Road, Zibo, 255000, China

    Chengli Jing, Guangming Zheng, Xiang Cheng, Yuxin Cui, Huanbao Liu & Huaqiang Zhang

Authors
  1. Chengli Jing
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Guangming Zheng
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Xiang Cheng
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Yuxin Cui
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Huanbao Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Huaqiang Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

CJ: conceptualization, methodology, formal analysis, investigation, writing—original draft, writing—review and editing. GZ: investigation, formal analysis, writing—review and editing, supervision. XC: conceptualization, writing—review and editing. YC: formal analysis. HL: investigation. HZ: supervision.

Corresponding author

Correspondence to Guangming Zheng.

Ethics declarations

Ethics approval

Not applicable.

Consent to participate

Not applicable.

Consent for publication

This work has been approved by all authors for publication.

Competing interests

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

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Jing, C., Zheng, G., Cheng, X. et al. Cutting performance and machining economy of the hard cutting tools in clean cutting of hardened H13 steel. Int J Adv Manuf Technol 130, 5165–5179 (2024). https://doi.org/10.1007/s00170-024-13012-0

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-024-13012-0

Keywords

Search

Navigation