Influence of different cooling strategies during hard turning of AISI 52100 - part I: thermo-mechanical load, tool wear, surface topography and manufacturing accuracy

Basten, Stephan; Kirsch, Benjamin; Ankener, Werner; Smaga, Marek; Beck, Tilmann; Uebel, Julian; Seewig, Jörg; Aurich, Jan C.

doi:10.1016/j.procir.2020.02.085

Cited by 10 publications

(3 citation statements)

References 20 publications

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“…The promoted heat transfer in superposition with the lubrication effects of the sub-zero MWF promotes a lower thermo-mechanical load when machining Ti-6Al-4V [38]. In previous works, the application of sub-zero cooling strategies resulted in less tool wear [39] and an optimized surface integrity [40,41] when turning Ti-6Al-4V. While milling Ti-6Al-4V, a favourable thermo-mechanical load has also been observed by us, which resulted in a better surface quality compared to a cryogenic cooling strategy [42].…”

Section: Introductionmentioning

confidence: 95%

Sub-zero milling of Ti-6Al-4V – Impact of the cutting parameters on the resulting forces, tool wear, and surface quality

Gutzeit

Bulun²,

Stelzer³

et al. 2023

Preprint

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Due to an excellent ratio of high strength and low density, Ti-6Al-4V is suitable for many industrial applications, especially in the aerospace industry. However, Ti-6Al-4V is also characterized as a hard to-cut material. This is mainly attributed to its very low thermal conductivity and high chemical reactivity, especially at elevated temperatures. Machining Ti-6Al-4V leads to high cutting temperatures and thermal loads of the tools within the cutting zone. This enhances a rapidly progressing, thermo-chemical induced tool wear reducing tool life and productivity. To enhance the cutting performance, suitable cooling strategies are a necessity to reduce the thermal load and hence to improve the machinability of Ti-6Al-4V. A novel, highly efficient cooling approach is to apply sub-zero metalworking fluids (MWF) at liquid state but at supply temperatures well below 0°C. These sub-zero MWF inhibit high cooling effects due to their low supply temperature in superposition with a beneficial wetting behavior. Within this paper, the application of a sub-zero cooling strategy is investigated and compared to a cryogenic CO2 cooling. The performance of both cooling strategies is analyzed when milling Ti-6Al-4V by systematically varying the cutting parameters and the milling strategy. The milling process is described on the basis of the occurring forces, the resulting wear and the surface quality. The results show that the sub-zero cooling outperforms the cryogenic CO2 cooling, especially at elevated cutting parameters and unfavorable cutting conditions. Less tool wear and an overall better surface quality are observed for sub-zero milling when being compared to cryogenic milling.

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Section: Introductionmentioning

confidence: 95%

Sub-zero milling of Ti-6Al-4V – Impact of the cutting parameters on the resulting forces, tool wear, and surface quality

Gutzeit

Bulun²,

Stelzer³

et al. 2023

Preprint

Self Cite

View full text Add to dashboard Cite

show abstract

“…Furthermore, the cooling concept influences the thermomechanical load collective and the residual stresses after machining. Basten et al [30] analyzed different cooling concepts for turning AISI 52100, namely dry cutting, CO 2 -snow, liquid nitrogen and a subzero metalworking fluid. The effects on the axial residual surface stresses are depicted in Figure 5.…”

Section: Causes and Modification Of Surface Layer Statesmentioning

confidence: 99%

The Present State of Surface Conditioning in Cutting and Grinding

Stampfer

González

Gerstenmeyer

et al. 2021

JMMP

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All manufacturing processes have an impact on the surface layer state of a component, which in turn significantly determines the properties of parts in service. Although these effects should certainly be exploited, knowledge on the conditioning of the surfaces during the final cutting and abrasive process of metal components is still only extremely limited today. The key challenges in regard comprise the process-oriented acquisition of suitable measurement signals and their use in robust process control with regard to the surface layer conditions. By mastering these challenges, the present demands for sustainability in production on the one hand and the material requirements in terms of lightweight construction strength on the other hand can be successfully met. In this review article completely new surface conditioning approaches are presented, which originate from the Priority Program 2086 of the Deutsche Forschungsgemeinschaft (DFG).

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“…The surface state during hard turning can also be affected by cooling conditions [ 18 ] when MQL and cryogenic cooling is employed. Tool wear and cooling conditions affect the accuracy of produced parts and surface integrity in the complexity of this term [ 19 ]. Attanasio et al [ 20 ] studied the influence of cutting speed and feed on WL and HAZ of AISI 52100, including the finite element model integrating the main aspects affecting the surface state.…”

Section: Introductionmentioning

confidence: 99%

Study of Residual Stresses and Austenite Gradients in the Surface after Hard Turning as a Function of Flank Wear and Cutting Speed

et al. 2023

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This paper investigates the influence of cutting speed and flank wear on the depth profile of residual stresses, as well as the fraction of retained austenite after hard turning of quenched bearing steel 100Cr6. Residual stress and retained austenite profiles were studied for the white layer, heat-affected zone thickness, and XRD sensing depth. It was found that the influence of flank wear on the white layer and heat-affected zone thickness predominates. On the other hand, residual stresses are affected the cutting speed and the superimposing contribution of flank wear. Moreover, these aspects also alter microhardness in the affected regions. The study also demonstrates that information concerning residual stresses and the austenite fraction is integrated into the white layer, and the heat-affected zone in the surface is produced by the insert of low flank wear since the XRD sensing depth is more than the thickness of the white layer. On the other hand, the pure contribution of the white layer or the heat-affected zone to residual stress and the austenite fraction can be investigated when the affected surface region is thick enough.

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Influence of different cooling strategies during hard turning of AISI 52100 - part I: thermo-mechanical load, tool wear, surface topography and manufacturing accuracy

Cited by 10 publications

References 20 publications

Sub-zero milling of Ti-6Al-4V – Impact of the cutting parameters on the resulting forces, tool wear, and surface quality

Sub-zero milling of Ti-6Al-4V – Impact of the cutting parameters on the resulting forces, tool wear, and surface quality

The Present State of Surface Conditioning in Cutting and Grinding

Study of Residual Stresses and Austenite Gradients in the Surface after Hard Turning as a Function of Flank Wear and Cutting Speed

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