Effect of Built-Up Edge Formation on Residual Stresses Induced by Dry Cutting of Normalized Steel

Abstract:

The tool and workpiece surface layer states of the tribosystem uncoated WC-Co cutting tools vs. normalised SAE 1045 workpiece material are studied in detail for a dry metal cutting process. Within the system the cutting parameters (cutting speed, feed rate, cutting depth) determine the wear state of the cutting tool and the resulting surface layer state (residual stress) in the workpiece. As the built-up edge can be used as a possible wear protecting layer [1] the influence of built-up edge and wear behaviour of the cutting tool was examined with respect to the workpiece surface layer state for knowledge based metal cutting processing. Small compressive stresses (-60-80 MPa) are induced in the surface layer, that are nearly homogeneous for the highest built-up edge, which lead to the lowest tool wear in combination with lowest cutting temperature.

• Periodical: Advanced Materials Research (Volume 996)
• Pages: 603-608
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.996.603
• Online since: August 2014
• Authors: Johannes Kümmel*, Jens Gibmeier, Volker Schulze, Alexander Wanner
• Keywords: Built-Up Edge, Cutting Tool Wear, Dry Cutting, Machining, Surface Layer

References

[1] J. Kümmel, J. Gibmeier, E. Müller, R. Schneider, V. Schulze, and A. Wanner. Detailed analysis of microstructure of intentionally formed built-up edges for improving wear behaviour in dry metal cutting process of steel. Wear, 311(1-2): 21-30, (2014).

DOI: 10.1016/j.wear.2013.12.012

[2] B. Scholtes. Eigenspannungen in mechanisch randschichtverformten Werkstoffzuständen: Ursachen, Ermittlung und Bewertung, DGM-Informationsgesellschaft, Oberursel, (1991).

DOI: 10.1002/mawe.19910221203

[3] J. Paulo Davim. Surface Integrity in Machining. Springer London, London, (2010).

[4] I.S. Jawahir, E. Brinksmeier, R. M'Saoubi, D.K. Aspinwall, J.C. Outeiro, D. Meyer, D. Umbrello, and A.D. Jayal. Surface integrity in material removal processes: Recent advances. CIRP Annals - Manufacturing Technology, 60(2): 603-626, (2011).

DOI: 10.1016/j.cirp.2011.05.002

[5] H. Autenrieth. Numerische Analyse der Mikrozerspanung am Beispiel von normalisiertem C45E. Dissertation, Universität Karlsruhe, (2010).

[6] C.R. Liu and M.M. Barash. Variables governing patterns of mechanical residual stress in a machined surface. Journal of Engineering for Industry, 104: 257-264, (1982).

DOI: 10.1115/1.3185828

[7] Q. Xie, A.E. Bayoumi, and L.A. Kendall. On tool wear and its effect on machined surface integrity. Journal of Materials Shaping Technology, 8: 255-265, (1990).

DOI: 10.1007/bf02833822

[8] E. Macherauch and P. Müller. Das sin²ψ-Verfahren in der röntgenographischen Spannungsmessung. Zeitschrift für angewandte Physik, 13: 305–316, (1961).

[9] B. Eigenmann and E. Macherauch. Röntgenographische Untersuchung von Spannungszuständen in Werkstoffen Teil III. Materialwissenschaft und Werkstofftechnik, 27(9): 426–437, (1996).

DOI: 10.1002/mawe.19960270907

[10] U. Wolfstieg. Die Symmetrisierung unsymmetrischer Interferenzlinien mit Hilfe von Spezialblenden. HTM - Härterei-Technische Mitteilungen, 31: 23–26, (1976).