CIRP Annals - Manufacturing Technology: T. O Zel, Y. Karpat, A. Srivastava
CIRP Annals - Manufacturing Technology: T. O Zel, Y. Karpat, A. Srivastava
CIRP Annals - Manufacturing Technology: T. O Zel, Y. Karpat, A. Srivastava
A R T I C L E I N F O
A B S T R A C T
Keywords:
Hard machining
Tool
Edge geometry
This paper presents investigations on hard turning with variable edge design PcBN inserts. Turning of
hardened AISI 4340 steel with uniform and variable edge design PcBN inserts is conducted, forces and
tool wear are measured. 3D nite element modelling is utilized to predict chip formation, forces,
temperatures and tool wear on uniform and variable edge micro-geometry tools. Predicted forces and
tool wear contours are compared with experiments. The temperature distributions and tool wear
contours demonstrate the advantages of variable edge micro-geometry design.
2008 CIRP.
1. Introduction
* Corresponding author.
0007-8506/$ see front matter 2008 CIRP.
doi:10.1016/j.cirp.2008.03.063
3. Experimental procedure
In this study, turning of annealed and hardened AISI 4340 steel
(40 HRc) using PcBN inserts (50% CBN + 40% TiC + 6% WC) with four
different micro-geometries (uniform chamfer with 0.1 mm chamfer
height and 208 angle, uniform hone with 50 mm (and 40 mm) edge
radius, waterfall (WF) hone with re = 30:60 mm radii, variable hone
edge with reA = 50 mm, reB = 10 mm radii) were considered. Turning
74
Fig. 1. Waterfall (re1:re2) and round (re) hone micro-geometry edge design.
0:258
1:14
F z 2670:4d
F c 6568d
0:895
V 0:437 f
V 0:327 f
V 0:160 f
0:466
0:327
0:695
r e0:0829
r e0:199
1
2
(1)
r e0:0478
r e0:112
1
2
(2)
r e0:0145
r e0:0053
1
2
(3)
m
e
T T0
1
T melt T 0
e 0
s A Ben 1 C ln
(4)
p [MPa]
h [kW m2 K1]
0
5
30
18
180
87
300
222
420
410
600
500
75
Table 2
Thermomechanical properties of work and tool materials
AISI 4340
PcBN
7850
205
0.29
475
44.5
12.3
4280
587
0.13
750
44
4.7
Table 3
Pressure-dependent shear friction factor
p [MPa]
m1
m2
500
0.4
0.2
1000
0.7
0.35
1500
0.8
0.4
2000
0.9
0.5
2500
1.0
0.7
Ft [N]
Fc [N]
Fz [N]
Tool [8C]
Chamfer
0.75
m1
299
386
700
775
236
335
1020
853
782
690
225
310
836
724
Uniform Hone, re = 40 mm
m2
354
m1
324
835
675
276
336
623
664
800
690
352
258
693
638
(5)
76
Acknowledgement
B. Kaftanoglu acknowledges support from Ministry of Industry
and Trade-Turkey, SANTEZ: 00028.STZ.2007-1.
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