Effect of Built-Up Edge Formation during Stable State of Wear in AISI 304 Stainless Steel on Machining Performance and Surface Integrity of the Machined Part

Abstract

During machining of stainless steels at low cutting -speeds, workpiece material tends to adhere to the cutting tool at the tool–chip interface, forming built-up edge (BUE). BUE has a great importance in machining processes; it can significantly modify the phenomenon in the cutting zone, directly affecting the workpiece surface integrity, cutting tool forces, and chip formation. The American Iron and Steel Institute (AISI) 304 stainless steel has a high tendency to form an unstable BUE, leading to deterioration of the surface quality. Therefore, it is necessary to understand the nature of the surface integrity induced during machining operations. Although many reports have been published on the effect of tool wear during machining of AISI 304 stainless steel on surface integrity, studies on the influence of the BUE phenomenon in the stable state of wear have not been investigated so far. The main goal of the present work is to investigate the close link between the BUE formation, surface integrity and cutting forces in the stable sate of wear for uncoated cutting tool during the cutting tests of AISI 304 stainless steel. The cutting parameters were chosen to induce BUE formation during machining. X-ray diffraction (XRD) method was used for measuring superficial residual stresses of the machined surface through the stable state of wear in the cutting and feed directions. In addition, surface roughness of the machined surface was investigated using the Alicona microscope and Scanning Electron Microscopy (SEM) was used to reveal the surface distortions created during the cutting process, combined with chip undersurface analyses. The investigated BUE formation during the stable state of wear showed that the BUE can cause a significant improvement in the surface integrity and cutting forces. Moreover, it can be used to compensate for tool wear through changing the tool geometry, leading to the protection of the cutting tool from wear.

Prediction and Optimization of Drilling Parameters in Drilling of AISI 304 and AISI 2205 Steels with PVD Monolayer and Multilayer Coated Drills

“…For a specific range of parameters, the experimental results from the Taguchi method and ANOVA analysis, show that the tool life decreases with increasing cutting speed. This phenomenon can be attributed to the low thermal conductivity of stainless steels, which leads to heat concentration in the cutting zone that results in high localized temperatures [24].…”

“…The tool life criterion was set to a flank wear of 0.3 mm (the period of cutting time until the average flank wear reached 0.3 mm) following the recommendation of the ISO 3685 Standard [24]. In the drilling experiments, a Kistler dynamometer 9271A with data acquisition system was used for measurement of the feed force and torque.…”

Tool Wear, Surface Topography, and Multi-Objective Optimization of Cutting Parameters during Machining AISI 304 Austenitic Stainless Steel Flange

“…This was related to work hardening behaviors of AISI 304. The depth of the hardened layer of AISI 304 austenitic stainless steel was 0.1-0.3 mm [25]. Therefore, avoiding a hardened layer as far as possible was beneficial to improving the quality of the machined surface.…”

Effect of Cutting Speed in the Turning Process of Aisi 1045 Steel on Cutting Force and Built-Up Edge (Bue) Characteristics of Carbide Cutting Tool

“…They can cause changes to the cutting tool geometry and the metal cutting process mechanism [9]. BUE chips that occur at the angle of the cutting tool are not permanently formed but are periodically released from cutting tools, and sometimes the chips are attached to the surface of the tools [9] [10].…”