Decomposition of cutting forces with respect to chip segmentation and white layer thickness when hard turning 100Cr6

Analysis of Surface State after Turning of High Tempered Bearing Steel

“…Separation of the shear and normal components Fαt, Fαtn, Fγt, and Fγtn was carried out by the use of a sample with a variable cutting depth [6]. Further details about the methodology, the employed equations, a brief sketch of the turned sample, and the appearance of tool wear land, can be found in the previous study [7]. The cutting edge geometry alterations were investigated by Alicona 5 device (IF-Edge MasterModule) (Alicona Imaging GmbH, Graz, Austria) at the different phases of VB.…”

“…As contrasted with the previous studies [5,6,8], this study provides deeper insight into pure contribution of the shear and normal components in the different regions and their relationship to the thermal load. As compared with the study of Wang and Liu [8] or our previous work [7], this study also discusses contribution of the thermal cycle duration, as well as the role of specific heat to the thickness of WL. Finally, as compared with [7], thermal cycle and the produced WL are investigated as a function of cutting speed and supplemented by the measurement of microhardness in WL.…”

“…As compared with the study of Wang and Liu [8] or our previous work [7], this study also discusses contribution of the thermal cycle duration, as well as the role of specific heat to the thickness of WL. Finally, as compared with [7], thermal cycle and the produced WL are investigated as a function of cutting speed and supplemented by the measurement of microhardness in WL.…”

“…Thermally softened layer (dark region) lying below the near surface WL usually cannot be recognized in the case of high tempered samples due to the shadowing effect of the previous tempering in the furnace during heat treatment. WL thickness is Materials 2022, 15, 1718 2 of 13 affected mainly by the size of VB region and the main cutting motion v c [4][5][6][7][8]. In contrast with grinding, dislocation density in WL after turning is usually higher, causing severely strained matrix [4,8,9].…”

Modelling of Grain Size Evolution with Different Approaches via FEM When Hard Machining of AISI 4140

“…The modelling results could be highly interesting from an industrial perspective as well. Since the FEM analyses are relatively time-consuming and cannot be used for monitoring a real process with respect to Surface Integrity, the accurate simulations can be utilized to calibrate a so-called Soft-Sensor, which is able to work with fast analytical empirical relations between the process forces and temperatures [33][34][35], in order to predict or avoid the possible formation of White Layers during the machining process. The calibrated Soft-Sensor could then be used to control the process and adjust related process parameters to increase the quality of machined parts [35].…”