Skip to main content
SpringerLink
Log in

Tool wear analysis in the machining of hardened steels

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

Abstract

The machinability of a material can be assessed using many output parameters of the machining process, tool life being undoubtedly the most common. Tool life depends mainly on the tool wear rate, which in turn is very dependent on the prevailing wear mechanisms. It is therefore very important to study and analyze correctly the possible wear mechanisms on the rake and flank faces of the tool. When machining materials with high hardness, usually over 35 HRC, the difficulties are enormous because of the high cutting forces and heat generated, causing rapid tool wear and short tool life. When the hardness exceeds 45 HRC, the difficulties are even worse because the chips change from continuous to serrated types formed by localized shearing, increasing forces and temperatures even further. To tackle these adversities, ceramic and ultra-hard (CBN) tool materials are normally used, although other materials are also suitable. In interrupted cutting, for example, cemented carbides are frequently used. Wear mechanism analysis in hard machining is thus of particular importance. This article analyzes the tool wear mechanisms that occur in the machining of several hardened steels during continuous and interrupted cutting. All the analyses were performed after the tools have reached the stipulated end of the tool life criteria. Different types of tool material, such as cubic boron nitride, ceramics, and PVD-coated carbide inserts applied in turning and milling operations had their wear mechanisms analyzed. The main goal of this work was not to compare the tool lives of the conditions tried but to provide a greater understanding of tool wear phenomena and thus contribute to the development of tools with improved properties. Most of the worn tools had their wear region analyzed using a scanning electronic microscope (SEM) with the help of energy dispersive spectroscopy (EDS) technique. The wear analysis performed using the pictures taken in the SEM/EDS system was based on the main literature of this field of knowledge.

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. Machado AR, Abrão AM, Coelho RT, da Silva MB (2015) Teoria da usinagem dos materiais [theory of materials in machining], 3ª Edição. Edgard Blucher, São Paulo [In Portuguese]

    Google Scholar 

  2. Trent EM, Wright PK (2000) Metal cutting, 4th edn. Butterworth-Heinemann, Boston

    Google Scholar 

  3. Diniz AE, Micaroni R, Hassui A (2010) Evaluating the effect of coolant pressure and flow rate on tool wear and tool life in the steel turning operation. Int J Adv Manuf Technol 50:1125–1133. doi:10.1007/s00170-010-2570-1

    Article  Google Scholar 

  4. Diniz AE, Marcondes FC, Coppini NL (2006) Tecnologia da Usinagem dos Materiais [technology of machining of materials], 5a Edição. Artliber Editora, São Paulo [in Portuguese]

    Google Scholar 

  5. Bhattacharyya SK, Ezugwu EO, Jawaid A (1989) The performance of ceramic tool materials for the machining of cast iron. Wear 135:147–159

    Article  Google Scholar 

  6. Johnson D (1996) Why cutting tools fail. Tooling & Production, Huebcore Communications Inc

    Google Scholar 

  7. Melo AC, Milan JCG, Silva MB, Machado AR (2006) Some observations on wear and damage in cemented carbide tools. J Braz Soc Mech Sci Eng 28(3):269–277. doi:10.1590/s1678-58782006000300004

    Article  Google Scholar 

  8. Sandvik (1994) Modern metal cutting, 1st edn., Sandvik Coromant Technical Editorial Department, Tofters Tryckeri, Sweden

  9. Pekelharing AJ (1984) The exit failure of cemented carbide face-milling cutters. Part 1—fundamentals and phenomena. Annals of the CIRP 33:47–50

    Article  Google Scholar 

  10. Wang CY, Xie YX, Qin Z, Lin HS, Yuan YH, Wang QM (2015) Wear and breakage of TiAlN and TiSiN coated carbide tools during high-speed milling of hardened steel. Wear 336-337:29–42. doi:10.1016/j.wear.2015.04.018

    Article  Google Scholar 

  11. Broniszewski K, Wozniak J, Czechowski K, Jaworska L, Olszyna A (2013) Al2O3–Mo cutting tools for machining hardened stainless steel. Wear 303:87–91. doi:10.1016/j.wear.2013.03.002

    Article  Google Scholar 

  12. Barry J, Byrne G (2001) Cutting tool wear in the machining of hardened steels—part I: alumina/TiC cutting tool wear. Wear 247:139–151

    Article  Google Scholar 

  13. Barry J, Byrne G (2001) Cutting tool wear in the machining of hardened steels—part II: cubic boron nitride cutting tool wear. Wear 247:152–160

    Article  Google Scholar 

  14. Klocke F, Brinksmeier E, Weinert K (2005) Capability profile of hard cutting and grinding processes. Ann CIRP 54:557–580

    Google Scholar 

  15. Abrão AM (1995) The machining of annealed and hardened steels using advanced ceramic tools. Doctoral Thesis University of, Birmingham

    Google Scholar 

  16. De Godoy VAA, Diniz AE (2011) Turning of interrupted and continuous hardened steel surfaces using ceramic and CBN cutting tools. J Mater Process Technol 211:1014–1025. doi:10.1016/j.jmatprotec.2011.01.002

    Article  Google Scholar 

  17. Sandvik Coromant Main Catalogue (2016). Available in: http://www.coromant.sandvik.com/. Accessed on 06 of July of 2016.

  18. Diniz AE, Oliveira AJ (2008) Hard turning of interrupted surfaces using CBN tools. J Mater Process Technol 195:275–281. doi:10.1016/j.jmatprotec.2007.05.022

    Article  Google Scholar 

  19. Camargo JC, Dominguez DS, Ezugwu EO, Machado AR (2014) Wear model in turning of hardened steel with PCBN tool. J Refract Met Hard Mater 47:61–70. doi:10.1016/j.ijrmhm.2014.06.019

    Article  Google Scholar 

  20. Bonfá MM (2013) Torneamento do Aço Endurecido AISI D6 Utilizando Mínima Quantidade de Fluido de Corte [Turning of AISI D6 Hardened Steel Using Minimum Quantity of Fluid], Master Dissertation, Programa de Pós-graduação em Engenharia Mecânica. Universidade Federal de Uberlândia, Uberlândia/MG [In Portuguese]

    Google Scholar 

  21. Oliveira AJ, Diniz AE (2009) Tool life and tool wear in the semi-finish milling of inclined surfaces. J Mater Process Technol 209:5448–5455. doi:10.1016/j.jmatprotec.2009.04.022

    Article  Google Scholar 

  22. Montalvao JA (2014) Determinação da Usinabilidade dos Aços - Ferramentas N2711M e VPATLAS no Fresamento de Topo [Determination of the machinability of N2711M and VPATLAS tool steels in end milling], master dissertation, Programa de Pós-graduação em Engenharia Mecânica. Universidade Federal de Uberlândia, Uberlândia/MG [In Portuguese]

    Google Scholar 

  23. Dos Santos ALB, Duarte MAV, Abrão AM, Machado AR (1999) An optimization procedure to determine the coefficients of the extended Taylor’s equation in machining. International Journal of Machine Tools & Manufacture 39:17–31

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. LEPU/FEMEC, Federal University of Uberlândia, Uberlândia, MG, 38400-902, Brazil

    Álisson Rocha Machado

  2. Graduate Program in Mechanical Engineering, Pontifícia Universidade Católica do Paraná – PUC-PR, Curitiba, PR, 80215-901, Brazil

    Álisson Rocha Machado

  3. College of Mechanical Engineering, University of Campinas (UNICAMP), Campinas, Brazil

    Anselmo Eduardo Diniz

Authors
  1. Álisson Rocha Machado
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Anselmo Eduardo Diniz
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Álisson Rocha Machado.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Machado, Á.R., Diniz, A.E. Tool wear analysis in the machining of hardened steels. Int J Adv Manuf Technol 92, 4095–4109 (2017). https://doi.org/10.1007/s00170-017-0455-2

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-017-0455-2

Keywords

Search

Navigation