Tool wear rate of the PCBN, mixed ceramic, and coated cemented carbide in the hard turning of the AISI 52100 steel

Boing, Denis; Zilli, Leonardo; Fries, Carlos Ernani; Schroeter, Rolf Bertrand

doi:10.1007/s00170-019-04295-9

Cited by 11 publications

(5 citation statements)

References 16 publications

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“…Dry cutting conditions are not only an environmentally friendly process but also economically affordable by neglecting the costs of purchasing and disposing of cutting fluids [38]. Hard-turning is usually performed with PCBN or mixed ceramic tools that are even harder than the machined material and can withstand the tribological conditions of the process [39]. Cubic boron nitride (CBN) tool material, which exhibits high toughness, high hardness, and a stable structure at high temperatures, is suitable for hardened steels.…”

Section: Methodsmentioning

confidence: 99%

Comparative Evaluation of Coated Carbide and CBN Inserts Performance in Dry Hard-Turning of AISI 4140 Steel Using Taguchi-Based Grey Relation Analysis

2023

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Dry hard-turning is a vital manufacturing method for machining hardened steel due to its low cost, high machining efficiency, and green environmental protection. This study aims to analyze the effect of various machining parameters on cutting forces and surface roughness by employing RSM and ANOVA. In addition, multi-objective optimization (Grey Relation Analysis: GRA) is performed to determine the optimum machining parameters. Dry hard-turning tests were carried out on AISI 4140 steel (50 HRC) using coated carbide and CBN inserts with different nose radii. The results show that the cutting force components are greatly affected by the cutting depth and cutting speed for both cutting inserts. As the level of cutting depth and cutting speed rise, the cutting forces also increase. However, the feed rate was the main factor in surface roughness. A low feed rate and high cutting speed lead to good surface quality. According to the results, CBN inserts exhibited better performance compared to carbide inserts in terms of minimum cutting forces and surface roughness. The lowest radial force (Fx = 55.59 N), tangential force (Fy = 15.09 N), cutting force (Fz = 30.49 N), and best surface quality (Ra = 0.28 µm, Rz = 1.8 µm) were obtained using a CBN tool. Finally, based on the GRA, the (V = 120 m/min, f = 0.04 mm/rev, a = 0.06 mm, r = 0.8 mm) have been chosen as optimum machining parameters to minimize all responses simultaneously in the machining of AISI 4140 steel using both carbide and CBN inserts.

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Section: Methodsmentioning

confidence: 99%

Comparative Evaluation of Coated Carbide and CBN Inserts Performance in Dry Hard-Turning of AISI 4140 Steel Using Taguchi-Based Grey Relation Analysis

2023

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“…In the end, comparatively high machining accuracy is achieved at a lower cost and with a lower environmental impact. This has a direct impact on the high efficiency and productivity of this treatment method [1,2]. However, the problem of replacing the grinding operation with turning lies in the necessity of selecting such machining parameters and such cutting tools for which the machined surface will be characterized by possibly low surface roughness, usually defined by the R a parameter in the required range of 0.1-2 µm, at the same time with a high material contribution to the roughness profile [3,4].…”

Section: Introductionmentioning

confidence: 99%

The Geometric Surface Structure of EN X153CrMoV12 Tool Steel after Finish Turning Using PCBN Cutting Tools

2021

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The article presents the results of studying the effects of coated (TiN, TiAlN) and uncoated polycrystalline cubic boron nitride (PCBN) machining blades on the key geometric structure parameters of the surface of hardened and tempered EN X153CrMoV12 steel after finish turning. A comparative analysis of the use of coated and coated cutting tools in finish turning of hardened steels was made. Tool materials based on polycrystalline cubic boron nitride PCBN (High-CBN; Low-CBN) have been described and characterized. The advantages of using TiN and TiAlN-coated cutting tools compared to uncoated were demonstrated. The lowest influence of the feed on the values of all tested roughness parameters was noted for surfaces treated with TiN- and TiAlN-coated tools (both with 50 vol.% of CBN). For uncoated tools (60 vol.% of CBN) for feeds f = 0.2 and 0.3 mm/rev., the highest values of Ra and Rz roughness parameters were found. Moreover, the lack of protective coating contributed to the occurrence of intense adhesive wear on the flank surface, which was also in the range of the feed values f = 0.2 and 0.3 mm/rev. The analysis of material surface after treatment with the uncoated tools with the feed f = 0.2 mm/rev. showed the occurrence of the phenomenon of lateral material flow and numerous chip deflections.

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“…Li et al [15] found that the multi-coated tool was suitable for the high-speed milling of AISI 4340 steel due to the high resistance of element diffusion. Boing [16] reported that the increase of tool wear rate with the cutting speed was different for each tool material in the hard turning of AISI 52100 steel.…”

Section: Introductionmentioning

confidence: 99%

A Fuzzy Evaluation of Tool Materials in the Turning of Marine Steels

Liu

Cai

et al. 2021

Metals

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To recommend one suitable tool material for the cutting of marine steels under special conditions and requirements in emergency rescues of capsized steel ships, the cermet tools, cemented carbide tools and coated carbide tools were evaluated using a fuzzy evaluation method concerning cutting force, cutting temperature, surface roughness and tool wear. Experimental results indicate that the tool cutting performance was diverse and difficult to evaluate with a single evaluation index. The cemented carbide tools presented bad cutting performance with severe wear. Compared with the cemented carbide tools, the cermet tools showed excellent wear resistance with about 60.3% smaller tool flank wear value and good surface quality with about 46.8% smaller surface roughness. The coated carbide tools presented low cutting temperatures about 15.6% smaller than those of the cermet tools. The result of fuzzy evaluation demonstrates that the cermet tools presented the best cutting performance, followed by the coated carbide tools, and then the cemented carbide tools. The cermet tools are recommended to cut marine steels in emergency rescues of capsized steel ships.

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Tool wear rate of the PCBN, mixed ceramic, and coated cemented carbide in the hard turning of the AISI 52100 steel

Cited by 11 publications

References 16 publications

Comparative Evaluation of Coated Carbide and CBN Inserts Performance in Dry Hard-Turning of AISI 4140 Steel Using Taguchi-Based Grey Relation Analysis

Comparative Evaluation of Coated Carbide and CBN Inserts Performance in Dry Hard-Turning of AISI 4140 Steel Using Taguchi-Based Grey Relation Analysis

The Geometric Surface Structure of EN X153CrMoV12 Tool Steel after Finish Turning Using PCBN Cutting Tools

A Fuzzy Evaluation of Tool Materials in the Turning of Marine Steels

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