Analysis of surface roughness parameters achieved by hard turning with the use of PCBN tools

Abstract

The turning of hardened steels has been applied in many cases in production. Currently, the most important problem is concerned with the properties of the surface finish. This paper investigates the effect on surface finish in a continuous dry turning of hardened steel when using polycrystalline cubic boron nitride tools. The surface profiles (2D arrangement) and surface topography (3D arrangement), generated during the hard turning operation on an EN 41Cr4 low chromium alloy steel, heat treated to the hardness of 58 HRC, were evaluated. This paper introduces the multiparameter characterization of the surface when cutting with different tool materials.

RSM Based Investigations on the Effects of Cutting Parameters on Surface Integrity during Cryogenic Hard Turning of AISI 52100

“…In recent past people associated with industrial production and scientific research have shown increasing interest in hard turning of steel since the process possesses a number of potential advantages, including lower equipment costs, shorter setup time, high accuracy, fewer process steps, greater part geometry flexibility, and usually there is no need to use cutting fluid during turning of hard steel. According to one estimate, use of hard turning in the manufacturing of complex parts could reduce manufacturing costs by up to 30 times [1,2] It has been reported that hard turning processes provide high level of accuracy in terms of the form and size, high quality of surface finish and surface integrity (SI) in workpieces [3]. SI generated in the part by a machining operation constitutes several factors such as roughness, hardness, residual stresses, micro-structural changes, etc.…”

Investigations on the Effect of CNC Dry Hard Turning Process Parameters on Surface Integrity: A Multi-performance Characteristics Optimization

“…Hard turning avoids the use of subsequent finishing processes as this process is characterized by a high level of accuracy in terms of the form and size, high quality of surface finish and surface integrity (SI ) in workpieces [3][4][5]. The establishment of adequate machining guidelines requires the study of several factors (roughness, hardness, residual stresses, micro-structural changes, etc.)…”

An Assessment of the Wear Characteristics of Microcutting Arrays Produced From Polycrystalline Diamond and Cubic Boron Nitride Composites

“…The type of wear depends upon the continuity or interruption of the tool-workpiece contact as well as on the CBN percentage in the PCBN composite: abrasive wear has been found in continuous cutting conditions, while chipping was found as an addition to abrasion in the interrupted cutting [1], [9], [25]. Although there is a body of literature reporting on the performance of both low and high-CBN grades in conventional machining, no studies have addressed wear/cutting performance of these materials micro-textured in such a way that they can be employed in grinding-type operations.…”

“…Laser ablation technology has been successfully used for the production of macro-features/edges for cutting inserts on ultra-hard materials with a variety of rake and clearance angles. The variation of the geometrical characteristics of the macro-cutting edges has been reported in literature: negative rake angles in the range -6°/-10° are typically utilised for Journal of Manufacturing Science and Engineering, Transactions of the ASME 5 PCBN composites [9]- [12] while rake angles of circa 0° have been used especially for single crystal diamond [13], [14]. While laser ablation has been widely employed for straight and profiled cutting of diamond [10], [11], there have not been many studies for generating geometrically controlled micro-features on flat and curved diamond surfaces until recently [7].…”

“…Due to its high hardness (second to diamond), polycrystalline cubic boron nitride (PCBN) has been used as cutting tool in hard turning of steel producing smooth (roughness, 0.95 μm) and uniform surfaces [9]. Five wear mechanisms have been identified for PCBN tool wear: abrasion, fatigue, adhesion, dissolution/diffusion and through tribochemical processes [23], [24].…”