Abstract
Performance of cutting tool in hard turning is significantly influenced by its microgeometry, such as edge radius. This study presents an experimental exploration to understand the effect of cutting edge radius on machining performance in terms of surface roughness and tool wear. The cutting tools (CBN) with three groups of nominal edge radius, 20, 30, and 40 μm, were used in the study. The cutting edge radii were characterized with an Alicona optical microscope, and variation of the edge radius was evaluated in this study. The machining tests were then conducted to experimentally assess the effect of cutting edge radius on surface quality and tool wear under different machining conditions. Three-level and two-factor experiments were designed in the test. The results in this study suggest that there is noticeable variation in the edge radius on a cutting tool with a certain nominal value of edge radius. The variations tend to be smaller with increase of the nominal value of edge radius. Besides, the results can be drawn that edge radii have a significant influence on surface roughness and tool wear. Considering all factors, the cutting tool with nominal edge radius of 30 μm demonstrate better machining performance among three groups of cutting tool in hard turning of AISI52100 steel.
Article PDF
Similar content being viewed by others
References
Özel T, Hsu TK, Zeren E (2005) Effects of cutting edge geometry, workpiece hardness, feed rate and cutting speed on surface roughness and forces in finish turning of hardened AISI H13 steel[J]. Int J Adv Manuf Technol 25(3–4):262–269
Chou YK, Song H (2004) Tool nose radius effects on finish hard turning[J]. J Mater Process Technol 148(2):259–268
Fulemova J, Janda Z (2014) Influence of the cutting edge radius and the cutting edge preparation on tool life and cutting forces at inserts with wiper geometry[J]. Procedia Engineering 69:565–573
Zhou JM, Walter H, Andersson M, Stahl JE (2003) Effect of chamfer angle on wear of PCBN cutting tool. Int J Mach Tools Manuf 43(3):301–305
Attanasio A, Umbrello D, Cappellini C, Rotella G, M’Saoubi R (2012) Tool wear effects on white and dark layer formation in hard turning of AISI 52100 steel[J]. Wear 286:98–107
Huang Y, Liang SY (2005) Modeling of cutting forces under hard turning conditions considering tool wear effect[J]. J Manuf Sci Eng 127(2):262–270
Huang P, Lee WB (2016) Cutting force prediction for ultra-precision diamond turning by considering the effect of tool edge radius[J]. Int J Mach Tools Manuf 109:1–7
Denkena B, Lucas A, Bassett E (2011) Effects of the cutting edge microgeometry on tool wear and its thermo-mechanical load[J]. CIRP Annals-Manufacturing Technology 60(1):73–76
Bassett E, Köhler J, Denkena B (2012) On the honed cutting edge and its side effects during orthogonal turning operations of AISI1045 with coated WC-Co inserts[J]. CIRP J Manuf Sci Technol 5(2):108–126
Karpuschewski B, Schmidt K, Prilukova J et al (2013) Influence of tool edge preparation on performance of ceramic tool inserts when hard turning[J]. J Mater Process Technol 213(11):1978–1988
Thiele JD, Melkote SN (1999) Effect of cutting edge geometry and workpiece hardness on surface generation in the finish hard turning of AISI 52100 steel[J]. J Mater Process Technol 94(2):216–226
Bartarya G, Choudhury SK (2012) State of the art in hard turning[J]. Int J Mach Tools Manuf 53(1):1–14
Wyen CF, Wegener K (2010) Influence of cutting edge radius on cutting forces in machining titanium[J]. CIRP Annals-Manufacturing Technology 59(1):93–96
Yakimets I, Richard C, Béranger G et al (2004) Laser peening processing effect on mechanical and tribological properties of rolling steel 100Cr6[J]. Wear 256(3):311–320
de Siqueira GG, Stipkovic Filho M, Batalha GF (2006) Hard turning of tempered DIN 100Cr6 steel with coated and no coated CBN inserts[J]. J Mater Process Technol 179(1):146–153
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
Open Access This article is distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution, and reproduction in any medium, provided you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license, and indicate if changes were made.
About this article
Cite this article
Zhao, T., Zhou, J.M., Bushlya, V. et al. 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 (2017). https://doi.org/10.1007/s00170-017-0065-z
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-017-0065-z