Hard Part Turning Fundamentals PDF
Hard Part Turning Fundamentals PDF
Hard Part Turning Fundamentals PDF
ally seeking ways to manufacture their parts with lower cost, higher quality,
rapid setups, lower investment, and smaller tooling inventory while eliminating
can satisfy each and every one of these goals. We’ll expore what hard turning
is, its advantages and limitations, the best machine for the job, and how to be
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We would like to thank the experts at Hardinge for providing the content for this white
paper. Their invaluable expertise and knowledge on not only the products but also the
hard turning process shows their commitment and support for the machining industry.
made from either CBN (Cubic Boron Nitride), Cermet • Surface finishes of 0.00011” (.003 mm)
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breviated grinding cycle. In some cases, the hard Hard turning is a viable process that has real and
turned surface may complete the operation and will measurable economic and quality benefits. This is
completely eliminate the grinding cycle altogether. particularly true with a machine tool that has a high
are representative, this list is certainly not conclusive 11 WAYS HARD TURNING REDUCES YOUR COST:
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02 THE ADVANTAGES + LIMITATIONS
KNOWING THE ADVANTAGES & LIMITATIONS Flexibility. Changes are easier if the part configuration
Grinding does--and likely always will--have a place in changes. And lathes can handle small lot sizes and
manufacturing, as all components can not be hard complex shapes much more efficiently than a grinding
turned due to tolerance requirements and the surface machine. Single-point turning of complex contours
However, hard turning does offer distinct advantages Environmental Issues. Lathes produce chips, which
when machining, including: are less costly to dispose of than the swarf produced
by grinding machines.
Price. Compared to grinding machines, lathes are
relatively inexpensive to purchase. Higher level grinders From the process standpoint, there are several areas
can perform multiple operations but are often more of consideration. With the correctly chosen cutting
expensive to operate due to setup and cycle times and tools, the hard turning process can support either
require more support equipment, such as balancers coolant cutting or dry cutting.
production control, shorter throughput and greater If the processing choice is to cut dry, then the tem-
chined with one set-up, resulting in less part handling Other considerations when dry cutting:
and less opportunity for part damage • Consider the workpiece temp when gaging
• Expect higher tool temperatures and lower tool life
Metal Removal. You can achieve up to 4-1 and 6-1 • Surface finish is generally not as good as cuts
made with coolant
higher metal removal rates. Low micro-inch finishes
• Protection from high temperature chips is required
can be achieved from 4 to 16 micro.
• Correctly choose tool material (i.e., not Ceramic)
• The chip salvage may be more cost effective
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Some applications may be sensitive to the surface There are several key items when choosing to operate
condition caused by “white layer” formation, which wet, and the first of these is the type of fluid to be
appears as a white layer at the surface of the material used. Generally, straight oils should be avoided be-
under metallographic examination. This layer depth cause of the inherent fire hazard. This is particularly
can vary greatly but for general discussions it is in the true if during a cut the coolant flow is disrupted and
area of 1 micro-meter (.0000040”/.00010mm) thick. the unquenched, high temperature chips contact the
According to Griffiths (1987), white layer can be caused Another point for wet operations is the importance to
by either 1) severe plastic deformation that causes properly direct the coolant flow by applying fluid to
rapid grain refinement or 2) phase transformations as both the top and the bottom of the tool tip simultane-
a result of rapid heating and quenching. White layer ously. Generated chip strings will frequently shield the
formation is not limited to hard turning operations coolant from the tool until the chip breaks away. The
but is also routinely found in grinding applications. It result is thermal shock and a process of degradation
is not desirable in products which have high contact of the cutting edge. Anticipate this when establishing
stresses and where fatigue failures can occur. the coolant nozzle locations from a slight sideward
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03 FINISH REQUIREMENTS + SPECIFICATIONS
FINISH REQUIREMENTS & SPECIFICATIONS able with multiple grades to suit different machining
part length-to-diameter ratio is up to 4:1 for unsup- • Hardest (suitable for plain diameters only)
ported workpieces, and up to 8:1 for parts with tail- • Medium (suitable for moderate interruption)
requirement may change these guidelines. Typical cutting data for CBN:
Cubic Boron Nitride (CBN) and are very economically priced compared to other
If the hardness ranges between 50-68 Rc and the depth types of inserts. The nature of the material necessi-
of hardness is greater than the depth of material to tates the use of blunt edge geometry, which inevitably
be removed, then Cubic Boron Nitride (CBN) is the increases cutting forces and reduces surface finish
best medium. CBN will give good tool life and wear potential.
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Typical cutting data for steel at 60 Rc: Natural & Synthetic Diamonds
• 315 feet per minute (96 m/min) Natural diamond and synthetic diamond are the least
• .005 “ (0.127 mm) depth of cut preferred options for operations involving machining
• .005” IPR (0.127 mm/rev) feedrate of hardened steel. They have high costs per edge
Cost per edge can be low, but failures on ceramic and poor reliability in terms of interrupted cuts and
inserts can be catastrophic, in which case all edges wear mode. Brazing cannot always be guaranteed
may not be usable. Ceramic also does not perform and re-grinding is not always possible. Diamond also
well in the presence of high thermal shocks, so it is interacts chemically with steels and can cause failure.
Cermet inserts for hardened steel turning applications is vital to the heat treat operator so that the cor-
have some benefits over CBN and ceramics under par- rect process and hardness range is accomplished.
ticular conditions. If the application involves turning Material not properly drawn back might crack prema-
through a hard case into a soft core, then cermet will turely because of the high hardness. The best hard
respond better than CBN. It does not have the wear turning results will be achieved when the hardness
resistance of CBN, but the tool tip will wear propor- range is as small as possible (a spread of less then
tionally under most circumstances rather than fail 2 point is ideal), and the case depth is maintained
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Hot Pressed v. Cold Pressed Hot Pressed AI2O3 + TiC (Black) Ceramics offer the
Hot pressed Ceramic and PCBN are made in a similar following features/benefits:
fashion. The material is mixed/formulated, then placed • Can hold +/-.001” (/.0254mm) on diameter
into a die cavity. For PCBN material that is to be used • Best for open tolerance parts
for tipping carbide inserts, a carbide backing layer is • Up to eight edges per insert
• Economically priced
placed into the die before the raw material.
• Use for roughing and finish with PCBN
• Good Toughness (has the ability to withstand
interrupted cutting)
• Good Hardness
• For continuous cutting, tool life can be as
good as PCBN
Under extreme pressure and temperature, the blank Kennametal K090 (Ceramic) is a TiC/alumina ce-
is formed and then ground, honed, and lapped. ramic (Black) Excellent edge wear provides good
speed/low-moderate
Different types of binders are used: Steels to 65 HRC, and Nickel-base alloys. Recom-
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Cold Pressed AI2O3 (White) Ceramics offer the There are only a few manufacturers of PCBN blanks;
Cold Pressed Ceramic • PCBN holds better surface finishes due to finer
micro-structure
are soft steels and soft
• Excellent toughness permits interrupted cutting
irons, though due to • Excellent hardness provides superior edge wear
the high AI2O3 content, • Chips take heat away from the part and tool
CBN inserts are produced through powdered metal HRC) with high and low
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04 THE IDEAL MACHINE FOR THE JOB
THE IDEAL MACHINE FOR HARD TURNING larger axis motors and shorter pitch ballscrews
solutions.
Success in Hard Turning is defined by a number
of factors:
• In addition, Hardinge is the largest manufacturer
• Machine rigidity
of lathe spindle tooling systems in the world. This
• Workholding Rigidity
ensures that the workholding systems made for
• Good vibration damping characteristics
• Rigid tool location our machines are designed specifically for our
• Machine Rigidity: Heavy-duty linear guideways plication of hard turning. HARCRETE is located
on Hardinge QUEST lathes are typically 40-60% in key positions of the base to assure maximum
heavier-duty units than those fitted to most com- rigidity. This unique design can help you save 30%
petitive machine tools of the same size. The low- or more on cutting tool expenses, and reduce
stress drive systems on QUEST machines have vibration at the spindle by 60%.
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Turning process.
and accuracy.
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05 TECHNIQUES FOR HARD TURNING SUCCESSFULLY
tiple standpoints. A machine which has improved approximately 1700 degrees (Fahrenheit). The majority
ing the amplitude of vibration and the time to decay, the cutting appli-
all while maintaining static stiffness. The real and cation should be
measurable results are longer tool life, better surface carried away with
and higher overall part quality. System rigidity is of heat increases tool
above: T
he illustration shows how this
utmost importance. wear and reduces heat should be dispersed.
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The key is to maximize rigidity. You should attempt Cutting forces are higher with negative rake.
center.
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Tool overhang should be kept as short as possible. magnified (see illustration above):
The maximum is 1 to 1-1/2 times the shank height • Torsional forces try to twist he bar
(see illustration below) Eliminate any shim or spacer. • Tangential forces try to deflect the bar away
There are versatile options for boring. Both Ceramic centerline. To counter this “centerline effect,” set the
and PCBN inserts are available in ANSI-standard ge- tool either on center or slightly above — NEVER below.
ometries. Most standard combination boring bars can (see illustration below).
ceramic inserts.
In general machining, you’ll experience tool deflection Lead angle cutting forces are at right angles to the
and chatter. In hard turning, the problems result- insert cutting edge. Lead angle geometry helps to
ing from tool pressure are multiplied, and forces are reduce edge chipping, and lead angle help protect the
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nose radius from surface conditions. The lead angle The chart below shows the relationship to length:diameter
permits the use of the 100-degree corner of the 80- ratio and the type of boring bar to be used.
pressure back to the spindle (see illustration below). LENGTH:DIAMETER RATIO BORING BAR
Up to 4:1 Steel
From 4:1 to 6:1 Steel with DeVibrator
From 4:1 to 6:1 Tungsten Carbide
From 4:1 to 6:1 Heavy-Metal Shank
From 6:1 to 8:1 Tungsten Carbide & DeVibrator
From 8:1 to 10:1 Tungsten Carbide & DeVibrator
Over 10:1 Special Tungsten Carbide
Composite with DeVibrator
and their relative merits. Single-point contact is “good,” The illustration below shows the correct application
Ericson or Collet Style is “better”, and Full-length split of coolant. The ideal application would be coolant
sleeve is “best.” supplied from above and below. The concept is simple.
Correct Incorrect
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06 NEXT STEPS
NEXT STEPS
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ABOUT GOSIGER
Since 1922, Gosiger has served the machine tool industry selling and servic-
ing top CNC machine brands including, Okuma and Hardinge. From Aerospace
equipment and technology you need to meet the challenges of today’s manu-
facturing business.
Our customers live in a world of intense pressure to make parts and products
better, faster and cheaper. They need a solution focused partner who under-
At Gosiger, we recognize that time is money. Our goal is to help you make it
right each and every time. We’re not simply a distributor of CNC machine tools
accomplish this goal, Gosiger offers a full array of support and services such as
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