Papers by Keyword: Hard Turning

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Authors: Gaurav Bartarya, S.K. Choudhury
Abstract: Forces in Hard turning can be used to evaluate the performance of the process. Cutting parameters have their own influence on the cutting forces on the tool. The present work is an attempt to develop a force prediction model based on full factorial design of experiments for machining EN31 steel (equivalent to AISI 52100 steel) using uncoated CBN tool. The force and surface roughness regression models were developed using the data from various set of experiments with in the range of parameters selected. The predictions from the models were compared with the measured force and surface roughness values. The ANOVA analysis was undertaken to test the goodness of fit of data.
Authors: Berend Denkena, Gerhard Poll, Oliver Maiß, Timo Neubauer
Abstract: The life time of roller bearings can be increased by inducing compressive residual stresses in the subsurface region of the raceway. These stresses can be induced by overloading in the first numbers of revolution. It would be much more useful to create the surface integrity within the manufacturing process. In this paper a method is presented to improve the process chain from grinding and honing to hard turning and deep rolling. As a result the surface finish is comparable to ground bearings. Due to the deep rolling process the maximum compressive stresses can be induced to higher values and depth. For the evaluation of the surface roughness in hard turning process and the maximum compressive stresses in deep rolling empirical models based on D-optimal experimental design are used.
Authors: Constatin Rotariu, Sevasti Mitsi, Dragos Paraschiv, Octavian Lupescu, Sergiu Lungu, Ana Bădănac, Mădălina Popa, Sorin Popa
Abstract: In this paper we analyze the influence of cutting parameters on the surface quality, surface roughness respectively, processed by turning when heat treated bearing steel, also called hard turning, and processing by turning of bearing steel without heat treatment. We set parameters of the cutting regime influencing the achievement of roughness surfaces which must be within the predetermined requirements if bearing rings exceeding 500 mm in diameter. This analysis will be done by statistical methods using the software Minitab 14.
Authors: Hai Dong Zhao, Li Bao An, Pei Qing Yang, Ye Geng
Abstract: Considerable research has been directed towards discovering new engineering materials for various applications. As a superhard material, Cubic Boron Nitride (CBN) has been developed and applied to engineering for several tens of years. Due to its high specific strength and stiffness as well as good creep, fatigue and wear resistance at elevated temperatures, CBN has been widely used as cutting tool material in manufacturing industry. In this paper, the preparation and characteristics of CBN are introduced. As hard turning has been more and more employed in recent years as an advanced metal cutting technique, the application of CBN cutting tools in hard turning is presented based on the literature, and in particular, the main wear mechanisms of CBN tools in hard turning are summarized, owing to the significant influence of tool wear on the tool life and product quality.
Authors: P.K. Mehrotra
Authors: Tao Chen, Yi Wen Wang, Yu Fu Li, C.J. Yang, Xian Li Liu
Abstract: In this paper, cutting experiment and FEM simulation are combined to investigate the effect of various chamfered edge geometries on cutting force and cutting temperature distribution when hardened steel GCr15(HRC60+2) is machined with PCBN tool. The research results indicate that radial force and main cutting force increase with the enlargement of chamfer angle, and especially, radial force rises more significantly, but radial force is less than main cutting force during the entire cutting process. Cutting temperature also gradually rises as chamfer angle increases, and moreover, it is maximized on the chip-tool interface in a place of 0.1-0.2mm distant from nose.
Authors: Yu Wang, Fu Gang Yan, Jing Shu Hu, Tao Chen, Zhen Chang, Xian Li Liu
Abstract: In this study, hard turning GCr15 bearing steel with high cutting speed is experimental investigated the influence of the CB7015WH insert with chamfer edge and Safe-Lock and the CB7015 insert with a combination of hone radius and a chamfer edge on cutting forces and surface roughness of machined surface. Experimental results show that the cutting forces of the chamfer edge and Safe-Lock is smaller than that of the combination of hone radius and a chamfer edge. Moreover, surface roughness of machined surface with the CB7015WH insert is better. A coupled thermo-mechanical 2D finite element model with general finite element analysis software Deform 2D.8.1 is developed for the influence of two kinds of inserts on cutting forces and effective stress. The simulation results are compared with experimental data and found to be in good agreement.
Authors: Ryutaro Tanaka, Hiroki Morishita, Yong Chuan Lin, Akira Hosokawa, Takashi Ueda, Tatsuaki Furumoto
Abstract: This study deals with the influence of tool characteristics on the cutting edge temperature in turning case hardened steel. The cutting test is undertaken with the inserts which have different thermal conductivity and coating layer. The tool edge temperature is measured with a two-color pyrometer. The tool edge temperature increases with the increase in cutting speed. The higher thermal conductivity cutting insert causes lower tool edge temperature. The coating hardly affects the tool edge temperature. The white layer thickness increases with increasing cutting speed reaching a maximum at certain cutting speed and decreases with cutting speed.
Authors: K. Venkatesh, T. Senthilvelan
Abstract: Hard turning is recent upcoming technology through which surface quality of machined components can be enhanced while comparing with the traditional grinding method. Since the absence of metal cutting fluids during this process, numerous harmful effects on shop floor operators and possible negative impacts on environment can be eliminated. Normally some of the vital machinability aspects such as surface integrity of machined parts has been influenced by magnitude of cutting temperature which evolved in metal cutting interface. Therefore in this experimental investigation, the influence of various process control parameters on tool-chip interface temperature was evaluated during hard turning of AISI D3 tool steel in dry condition. The machining trials were conducted as per the L9 Taguchi DOE approach and subsequent experimental data were analysed with the use of Design-Expert® V7 statistical software. This experiment results revealed that feed rate is having predominant influence in determining the magnitude of cutting temperature followed by depth of cut and cutting speed whereas the influence of cutting tool nose radius is insignificant.
Authors: M. Sayuti, Ahmed A.D. Sarhan, S. Salem
Abstract: In recent years, the energy efficiency improvement has become significant due to rapid consumption of world's energy resources. Particularly in manufacturing industry, hard turning process is one of the most fundamental metal removal processes that require huge power consumption and it could be improved in term of energy usage by many alternatives. At the same time, the improvement in term of machined surface quality is become a need since it would reflect appearance, performance and reliability of the products. As for example in the CNC machining field, one of the solution for this issue is by increasing the effectiveness of the existing lubrication systems as it could improve the machined surface quality, reduce the power required to overcome the friction component in batch production of machining process and reduce the oil consumption. The effectiveness of the lubrication system could be improved by introducing the nanobase lubrication system for much less power consumption as the rolling action of billions units of nanoparticle in the tool chip interface could reduce the cutting forces significantly. In this research work, the possibility of using SiO2 nanobase lubrication system is investigated to reduce the machining power consumption as well as improving surface quality in hard turning process of AISI4140.
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