Tool Wear Effect on Surface Integrity in AISI 1045 Steel Dry Turning

Abstract

In the present work, the surface integrity and flank wear of uncoated cermet inserts in dry turning of AISI 1045 steel were evaluated. Three-dimensional techniques were used to assess the surface roughness. Previously, finite element analysis was carried out to predict the cutting forces and heat distribution in the chip formation region. Cutting speed and feed were the parameters varied in the experiments. Feed is decisive in the final quality of the turned surface and cutting speed had little influence on this aspect. The surface was significantly damaged with the progression of the insert flank wear. Considering an average flank wear VBB of 0.1 mm, a tool life of 35 min was achieved using a cutting speed of 175 m/min, and of 23 min for a cutting speed of 275 m/min. Abrasive wear was predominant during the experiments. No microstructure defects were observed, as well as crack propagation or accentuated deformations near the machined surface region. Therefore, the dry turning of 1045 steel with cermet inserts route has proven extremely viable from the standpoints of tool life, surface integrity, chip formation, and sustainability.

The effects of coolant on the cutting temperature, surface roughness and tool wear in turning operations of Ti6Al4V alloy

“…Excessive wear of cutting tool and hence short life of cutter are created due to generated heat in the cutting zone and dispersion of material expansion which can decrease the surface quality of machined components (Uzun et al 2022;Shalaby and Veldhuis 2019). Tool wear has an impact on not only tool life, but also the quality of the finished product in terms of dimensional accuracy as well as surface integrity of machined components (Magalhães et al 2022). Moreover, the ultimate surface roughness of machined components is one of the most essential factor in machining operations which should be investigated in terms of quality enhancement of machined parts (Hatefi and Abou-El-Hossein 2020).…”

Prediction of Surface Roughness in Turning Applying the Model of Nonlinear Oscillator with Complex Deflection

“…Upadhyay et al [1] and González-Laguna, A. et al [24] extended the conclusion by analyzing the measured vibration signals. Based on the measured results it is concluded that the vibration properties, but also the roughness of the surface and the wear in turning [25], depend on the cutting tool parameters [26] and also on cutting parameters [27] e.g., speed, depth of cut, lubrication conditions and feed rate [12]. In addition, it is seen that based on the measured vibration properties of the system the prediction of the surface roughness is possible.…”

“…Thus, experiments are done for workpieces made of various materials such as Ti-6Al-4V [1,2], dry grey cast iron [3], Inconel 718 alloy [4], stainless steel [5][6][7], for AISI 5140 [8], and AISI 316L steel for biomedical purposes [9]. The roughness properties of the turning EN19 steel, cut with the coated carbide tool [10], AISID2 turning with minimal quantity of lubrication (MQL) [11], dry turning [12] and hard turning of AISI 52100 steel [13], and Haynes 263 and Inconel 718 superalloys turning with cryogenic cooling [14] have also been considered. The obtained results show that the roughness level differs for various workpieces and turning properties and parameters.…”

Coupling Taguchi Experimental Designs with Deep Adaptive Learning Enhanced Artificial Intelligence Process Models: A Novel Case in Promising Experimental Cost Savings Possibilities in Manufacturing Process Development

“…The selection of operational parameters with rightly configured combination is an important criterion especially for dry finishing machining operations [25][26][27]. According to previous research work, for dry finishing turning operations depth of cut (DOC), feed rate (FR) and cutting speed (CS) are critical operational parameters [23][24][25][26][27].…”