The Effect of Cutting Tool Geometry on Surface Integrity: A Case Study of CBN Tools and the Inner Surface of Bearing Rings

Abstract

In this paper, a practical issue of the application of cubic boron nitride (CBN) cutting tools for the machining of steel 100Cr6 thin-walled bearing rings is addressed. Three geometries of the commercially available CBN cutting inserts were tested at different machining parameters. The effect of geometry was assessed in terms of surface integrity, considering 2D profile parameters, 3D topography of the surface, and residual stresses in the surface layer. The results were sometimes contradictory, since the same cutting inserts provided the largest and the lowest values of the topography parameters, dependent on different cutting conditions. In general, CBN cutting inserts with XCEL geometry ensured the smallest profile parameters Ra and Rz, and the spatial parameters of Smr1 exhibited the largest values among all tested tools, suggesting reduced wear resistance. Residual stresses analysis did not reveal any inacceptable or potentially dangerous surface layer state after machining.

Challenges of Engineering Applications of Descriptive Geometry

“…By changing the surface roughness, the friction between the motion-transmitting machine parts, as well as the wear and corrosion resistance, and the creep strength of the parts can be influenced [9]. Although the evaluation of surface quality is applied with 2D parameters during engineering practice, the analysis of the microtopography of the curved surfaces with a 3D optical microscope also provides information about the integrity of the surface, for which it is also necessary to determine the appropriate viewpoints [10]. In an additional area of research, finite element tests of a 2D cross-section are carried out for the analysis of 3D cylindrical industrial facilities and the physical phenomena occurring in them, for example also in thermal models prepared for individual industrial applications.…”