An experimental study on the effect of tool geometry on tool wear and surface roughness in hard turning

Abstract

The main purpose of this study is to investigate the influence of tool geometry (cutting edge angle, rake angle, and inclination angle) and to optimize tool wear and surface roughness in hard turning of AISI 1055 (52HRC) hardened steel by using TiN coated mixed ceramic inserts. The results show that the inclination angle is the major factor affecting the tool wear and the surface roughness in hard turning. With the increase in negative rake and inclination angles, the tool wear decreases, and the surface roughness increases. However, the surface roughness will decrease when the inclination angle increases to overpass a certain limit. This is a new and significant point in the research of the hard turning process. From this result, the large negative inclination angle (λ = −10°) should be applied to reduce the surface roughness and the tool wear simultaneously. With the optimal cutting tool angles in the research, the hard machining process is improved remarkably with decreases of surface roughness and tool wear 8.3% and 41.3%, respectively in comparison with the standard tool angles. And the proposed tool-post design approach brings an effective method to change the tool insert angles using standard tool-holders to improve hard or other difficult-to-cut materials turning quality.

Multi-axis CNC finishing and surface roughness prediction of TC11 titanium alloy open integral micro impeller

“…48 It is frequently used to address real-world issues involving multi-factor interaction because its response prediction results can also approximate the true response surface and produce the optimum prediction effect. 49 Equation (4) illustrates how the second-order response surface approach expands the Taylor expansion for a single variable to multiple variables 50 :…”

Training on Tool Grinding for Teachers, SMK Muhammadiyah, 1 Klaten Utara, Central Java

“…During sharpening, students and teachers only assess sharpness visually and do not pay attention to the important geometric angles of the cutting tool. Incorrect tool geometry will increase vibration during cutting, accelerate tool wear, and result in rough surface finish (Duc et al, 2020) (Sonia et al, 2013). HSS cutting tool angles are formed by sharpening them with a tool grinder machine, and the angle measurements need to be ensured using measuring tools (Setyawan, 2011) (Sugeng, 2017).…”

Surface Integrity and Tool Wear Analysis on Turning of Copper-Nickel 70/30 ASTM B122 Alloy under Low Initial Lubrication

“…Mane et al [5] also reported that the depth of cut does not influence on the control of surface roughness when turning steel. For their part, Duc et al [6] found that the inclination angle is the major factor affecting the tool wear and the surface roughness on hard turning and that there is an optimal inclination and rake angle that provides the best cutting condition. Besides, tool wear affects the evolution of surface roughness and, in addition, friction coefficient depends on the adhesion and surface integrity of the machined part.…”