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Surface integrity assessment of M3 HSS cutting taps after grinding at various machining conditions

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Abstract

Grinding is a machining process that provides a combination of good surface finishing and tight dimensional tolerances on a machined component. Owing to these characteristics, it is employed in the finishing process of hardened parts, such as high-speed steel (HSS) cutting tools (principally drills and taps). Despite the various benefits, the specific energy in grinding is very high, resulting in high heat generated in the wheel–workpiece interface that could lead to thermal damages. To avoid such problems, aiming to maximize productivity and preserve the integrity of the machined component, a cutting fluid and cutting parameters must be properly selected. However, since the process dynamics is particular for each grinding process, especially in complex geometries, specific studies in real manufacturing conditions are required to understand the phenomena and minimize surface damages. In this context, this work aims to evaluate the surface integrity of M3 HSS cutting taps after they have been ground at various cutting conditions. Machining tests were performed in situ under controlled and variable wheel speed, depth of cut, and workpiece speed conditions. Machined surface images and microhardness below the surface were the output variables investigated. Results showed that, on average, the thickness of the affected surface layer was about 70% lower after machining at the lowest workpiece speed used. The correlation between grinding removal rates and thermal damage was also discussed.

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Funding

Two of the authors thank the Post-Graduate Program in Mechanical Engineering of the Federal University of Uberlândia, CAPES-Proex, and CNPq for the financial support. One of the authors thanks FAPEMIG for the financial support received through PPM-VII Project, Process No. PPM-00265-13 as well as the CAPES for the financial support given by a PNDP project—post-doctoral scholarship at the Post-Graduate Program of Electrical Engineering of FEB-UNESP-BAURU (2016–2017).

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Authors and Affiliations

  1. Department of Mechanical Engineering, São Paulo State University “Júlio de Mesquita Filho”, Bauru Campus, Av.Eng. Luiz Edmundo C. Coube, 14-01 – Vargem Limpa, Bauru, Sao Paulo, 17033-360, Brazil

    Saimon Vendrame, Eduardo Carlos Bianchi, Paulo Roberto Aguiar & Luiz Eduardo de Angelo Sanchez

  2. School of Mechanical Engineering, Joao Naves de Ávila Avenue, Federal University of Uberlândia - UFU, 2121 – Campus Santa Monica, Uberlândia, Minas Gerais, 38408-100, Brazil

    Rosemar Batista da Silva, Álisson Rocha Machado & Fabrício Guimarães Baptista

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

    Álisson Rocha Machado

  4. Kansas State University, Polytechnic Campus, 2310 - Centennial Road, Salina, KS, 67401-8196, USA

    Mark J. Jackson

Authors
  1. Saimon Vendrame
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  2. Rosemar Batista da Silva
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  3. Álisson Rocha Machado
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  4. Eduardo Carlos Bianchi
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  5. Paulo Roberto Aguiar
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  6. Fabrício Guimarães Baptista
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  7. Luiz Eduardo de Angelo Sanchez
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  8. Mark J. Jackson
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Correspondence to Saimon Vendrame.

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Vendrame, S., da Silva, R.B., Machado, Á.R. et al. Surface integrity assessment of M3 HSS cutting taps after grinding at various machining conditions. Int J Adv Manuf Technol 98, 617–627 (2018). https://doi.org/10.1007/s00170-018-2245-x

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  • DOI: https://doi.org/10.1007/s00170-018-2245-x

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