The Influence of Tool Rake Surface Geometry on the Hard Turning Process of AISI52100 Hardened Steel

Xu, Hanzhong; Zhou, Honggen; Ma, Zhengyu; Dai, Lei; Jing, Xuwen; Li, Guochao; Sun, Yujing

doi:10.3390/ma12193096

Cited by 6 publications

(5 citation statements)

References 40 publications

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“…A number of projects have compared the cutting performance of wiper and conventional inserts based on experimental work [12] or finite element simulation [32,33]. Wiper inserts produced a noticeable improvement in achievable surface quality compared with conventional insert [34], revealing the possibility of achieving smoother surfaces at higher feed rates.…”

Section: Introductionmentioning

confidence: 99%

On the Assessment of Surface Quality and Productivity Aspects in Precision Hard Turning of AISI 4340 Steel Alloy: Relative Performance of Wiper vs. Conventional Inserts

et al. 2020

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This article reports an experimental assessment of surface quality generated in the precision turning of AISI 4340 steel alloy using conventional round and wiper nose inserts for different cutting conditions. A three-factor (each at 4 levels) full factorial design of experiment was followed for feed rate, cutting speed, and depth of cut, with resulting machined surface quality characterized by resulting average roughness (Ra). The results show that, for the provided range of cutting conditions, lower surface roughness values were obtained using wiper inserts compared with conventional inserts, indicating a superior performance. When including the type of insert as a qualitative factor, ANOVA revealed that the type of insert was most important in determining surface roughness and material removal rate, with feed rate as the second most significant, followed by the interaction of feed rate and type of insert. It was found that using wiper inserts allowed simultaneous increases in feed rate, cutting speed, and depth of cut, while providing better surface quality of lower Ra, compared to the global minimum value that could be achieved using the conventional insert. These findings show that wiper inserts produce better surface quality and a material removal rate up to ten times higher than that obtained with conventional inserts. This clearly indicates the tremendous advantages of high surface quality and productivity that wiper inserts can offer when compared with the conventional round nose type in precision hard turning of AISI 4340 alloy steel.

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Section: Introductionmentioning

confidence: 99%

On the Assessment of Surface Quality and Productivity Aspects in Precision Hard Turning of AISI 4340 Steel Alloy: Relative Performance of Wiper vs. Conventional Inserts

et al. 2020

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“…ε and temperature T. Appropriate material parameters A, B, C, n, and m are listed in Table 1. As the cropping of long metal bars is the first process before forging, the bar material has not yet undergone hardening and tempering, and thus, the strength and hardness are not so high [19].…”

Section: Details Of the Fe Modelmentioning

confidence: 99%

“…Currently, the 1020 and 1045 steel bars with a diameter less than 50 cm are usually cropped by traditional shearing methods, which is highly efficient but causes obvious draw-in distortion. AISI 52100 and 304 steel are typical hard-to-cut steels; the former has high strength [19], and the latter has a high fracture toughness (J IC > 150 kJ/m 2 ) and good ductility [20]. Both types are usually cropped by sawing or the hot-shearing method.…”

Section: Introductionmentioning

confidence: 99%

Investigation of Notch-Induced Precise Splitting of Different Bar Materials under High-Speed Load

et al. 2020

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A notch-induced high-speed splitting method was developed for high-quality cropping of metal bars using a new type of electric-pneumatic counter hammer. Theoretical equations and FE models were established to reveal the crack initiation and fracture mode. Comparative tests were conducted for notched and unnotched bars of four types of steels, i.e., AISI 1020, 1045, 52100, and 304, and the section quality and microfracture mechanism were further investigated. The results show that damage initiates at the bilateral notch tips with peak equivalent plastic strain, and propagates through the plane induced by the notch tip; the stress triaxiality varies as a quasi-sine curve, revealing that the material is subjected to pure shearing at the notch tip, and under compression at the adjacent region. High precision chamfered billets were obtained with roundness errors of 1.1–2.8%, bending deflections of 0.5–1.5mm, and angles of inclination of 0.7°–3.4°. Additionally, the notch effectively reduced the maximum impact force by 21.6–23.9%, splitting displacement by 7.6–18.6%, and impact energy by 27.8–39.1%. The crack initiation zone displayed quasi-parabolic shallow dimples due to shear stress, and the pinning effect was larger in AISI 52100 and 1045 steel; the final rupture zone was characterized by less elongated and quasi-equiaxial deeper dimples due to the combination of shear and normal stress.

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“…e authors found that an increase in cuttingedge radius reduced TW. Xu et al studied the hard machining of AISI 52100 steel and found that changing tool rake surface geometry significantly reduced cutting temperatures, CF, and residual stresses, compared to the flat tool [15]. However, it also lowered the strength of the cutting edge.…”

Section: Introductionmentioning

confidence: 99%

Modeling and Optimizing the Effects of Insert Angles on Hard Turning Performance

Duc

Dai

Giang

2021

Mathematical Problems in Engineering

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To analyze hard turning performance characteristics, a new mathematical model was developed for the hard turning process, and cutting force (CF), another important response for cutting machining, was also studied in the present work. The analysis of the mathematical model and experimental results revealed that thrust force (Fy) was the largest, followed by tangential force (Fz) and feed force (Fx). The resultant CF was most influenced by inclination angle (IA) with 25.02%, followed by rake angle (RA) (14.26%) and cutting edge angle (CEA) (10.04%). Increasing CEA changed the position of cutting on the tool-nose radius and increased local negative RA and correspondingly local clearance angle (CA). Meanwhile, increasing negative RA and IA resulted in larger local negative RA and CA. Moreover, local RA and local CA were the main geometric factors affecting surface roughness (SR), tool wear (TW), and CF. Increasing local negative RA resulted in higher SR and CF. In contrast, increasing local CA resulted in lower SR, TW, and CF. Under specific conditions, the positive effects of the local CA overcame the negative effects of the local negative RA, leading to a simultaneous decrease in SR and TW. The proposed novel mathematical model can be further applied to calculate local CF, cutting temperature, and TW for each cutting-edge element, to analyze and optimize the hard turning process.

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The Influence of Tool Rake Surface Geometry on the Hard Turning Process of AISI52100 Hardened Steel

Cited by 6 publications

References 40 publications

On the Assessment of Surface Quality and Productivity Aspects in Precision Hard Turning of AISI 4340 Steel Alloy: Relative Performance of Wiper vs. Conventional Inserts

On the Assessment of Surface Quality and Productivity Aspects in Precision Hard Turning of AISI 4340 Steel Alloy: Relative Performance of Wiper vs. Conventional Inserts

Investigation of Notch-Induced Precise Splitting of Different Bar Materials under High-Speed Load

Modeling and Optimizing the Effects of Insert Angles on Hard Turning Performance

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