切削刃的几何形状工件硬度的影响进给速度和切削速度对表面粗糙度和力量完成硬化AISI H13钢车削外文文献翻译.docx
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切削刃的几何形状工件硬度的影响进给速度和切削速度对表面粗糙度和力量完成硬化AISI H13钢车削外文文献翻译.docx
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切削刃的几何形状工件硬度的影响进给速度和切削速度对表面粗糙度和力量完成硬化AISIH13钢车削外文文献翻译
EFFECTSOFCUTTINGEDGEGEOMETRY,WORKPIECEHARDNESS,FEEDRATEANDCUTTINGSPEEDONSURFACEROUGHNESSANDFORCESINFINISHTURNINGOFHARDENEDAISIH13STEEL
TugrulÖzel,Tsu-KongHsu,ErolZeren
DepartmentofIndustrialandSystemsEngineeringRutgers,TheStateUniversityofNewJersey,NewJersey08854USA
Abstract
Inthisstudy,effectsofcuttingedgegeometry,workpiecehardness,feedrateandcuttingspeedonsurfaceroughnessandresultantforcesinthefinishhardturningofAISIH13steelwereexperimentallyinvestigated.Cubicboronnitriteinsertswithtwodistinctedgepreparationsandthrough-hardenedAISIH-13steelbarswereused.Fourfactor(hardness,edgegeometry,feedrateandcuttingspeed)-twolevelfractionalexperimentswereconductedandstatisticalanalysisofvariancewasperformed.Duringhardturningexperiments,threecomponentsoftoolforcesandroughnessofthemachinedsurfaceweremeasured.Thisstudyshowsthattheeffectsofworkpiecehardness,cuttingedgegeometry,feedrateandcuttingspeedonsurfaceroughnessarestatisticallysignificant.Theeffectsoftwo-factorinteractionsoftheedgegeometryandtheworkpiecehardness,theedgegeometryandthefeedrate,andthecuttingspeedandfeedratearealsoappearedtobeimportant.Especially,smalledgeradiusandlowerworkpiecesurfacehardnessresultedinbettersurfaceroughness.Cuttingedgegeometry,workpiecehardnessandcuttingspeedarefoundtobeaffectingforcecomponents.Thelowerworkpiecesurfacehardnessandsmalledgeradiusresultedinlowertangentialandradialforces.
1.INTRODUCTION
Hardturning,machiningferrousmetalpartsthatarehardenedusuallybetween45-70HRC,canbeperformeddryusingpolycrystallinecubicboronnitride(PCBN,commonlyCBN)cuttingtoolsasextensivelyreportedinliterature[1-8].Researchresultsintheliteratureconcerningmechanismofserratedchipformationinordertorelateprocesscharacteristicsandstabilityofcuttingtothechipshapesduringhardturning[9-19].Otherresearchconcerningwithcomposition,temperaturesandwearcharacteristicsofCBNcuttingtools[1,8,20,21,22,28]andeffectsofworkmaterialproperties,toolgeometryandcuttingconditionsonsurfaceintegrityofthefinishmachinedparts[23-28]indicatechallengesinhardturningandidentifiesvariousprocess,equipmentandtoolingrelatedfactorsaffectingsurfacequality,toollifeandproductivity.Afterreviewingtheliterature,factorsaffectingforces,toolwear/failureandroughnessandintegrityofthefinishedsurfacesinhardturningusingCBNcuttingtoolsandtheirinfluencesoneachotherareillustratedwithachartshowninFig.1.Inthischart,theparametersabovethehorizontaldashedlinesareconsideredasfactorsorinputstothehardturningprocessandtheycanonlybeselectedinthebeginningexcepttoolvibration.Allotherparameters,thatarelocatedbelowthesedashedlines,consideredasperformancemeasuresoroutputsofthehardturningprocess.Reviewoftheliteraturerevealsthatalmostallofthefactorsgiveninthischartaffectperformanceofthehardturningprocess.Thosefactorscanbeclassifiedasfollows:
1.1Cuttingtoolgeometryandmaterialproperties
HardturningwithCBNcuttingtoolsdemandsprudentdesignoftoolgeometry.CBNcuttingtoolshavelowertoughnessthanothercommontoolmaterials,thuschippingismorelikely[2].Therefore,anoseradiusandproperedgepreparationareessentialtoincreasethestrengthofcuttingedgeandattainfavorablesurfacecharacteristicsonfinishedmetalcomponents[23].CBNcuttingtoolsdesignedforhardturningfeaturenegativerakegeometryandedgepreparation(achamferorahone,orevenboth).Specificationsoftheedgepreparationdesignareoftenfinalizedafterextensiveexperimentation.Fig.2showsthetypesofedgepreparationscommonforCBNcuttingtools.Accordingtorecentstudies,itisevidentthateffectofedgegeometryonsurfacequalityissignificant[23-28].
Fig.1.Aflowchartillustratingrelationshipsoffactorsinhardturning.
Theileetal.[24,25],presentedresearchresultsofanexperimentalinvestigationofeffectsofcuttingedgegeometryandworkpiecehardnessonresidualstressesinfinishhardturningofAISI52100steel.Theyindicatedthatbothfactorsaresignificantforthesurfaceintegrityoffinishhardturnedcomponents.Specifically,theyshowedthatlargehoneradiustoolsproducemorecompressivestresses,butalsoleave“white-layers”.Özel[26]investigatedtheinfluenceofedgegeometryinCBNtoolswithrespecttostressandtemperaturedevelopmentthroughfiniteelementsimulationsinhardturning.Chouetal.[28]experimentallyinvestigatedtheinfluenceofCBNcontentonsurfacequalityandtoolwearinhardenedAISI52100steeltool.ThisstudyconcludedthatlowcontentCBNtoolsproducebettersurfaceroughnesswithrespecttohighercontentCBNtoolsanddepthofcuthasminoreffectontoolwearrate.
Fig.2.TypeofedgepreparationsforCBNcuttingtools.
1.2Workpiecehardness
Duetothechangesinpropertiesofhardenedworkpiecematerial,basicshearingprocessandformationofchipsdifferinhardturning[5].PriorresearchshowedthatworkpiecehardnesshasaprofoundeffectontheperformanceoftheCBNtools[1,2,8]andalsointegrityoffinishmachinedsurfaces[23,25].Matsumotoetal.[23]andThieleetal.[25]studiedtheeffectofworkpiecehardnessonresidualstresses.Inarecentstudy,GuoandLiu[27]investigatedmaterialpropertiesofhardenedAISI52100bearingsteelusingtemperaturecontrolledtensiletestsandorthogonalcuttingtestsanddemonstratedthathardnessgreatlyinfluencesthematerialpropertiesaccountingforhighvariationinflowstressproperties.
1.3Cuttingspeed,feedrateanddepthofcut
PerformanceofCBNcuttingtoolsishighlydependentonthecuttingconditionsi.e.cuttingspeed,feed,feed-rate,anddepthofcut[7].Especiallycuttingspeedanddepthofcutsignificantlyinfluencetoollife[22].Increasedcuttingspeedanddepthofcutresultinincreasedtemperaturesatthecuttingzone.SinceCBNisaceramicmaterial,atelevatedtemperatureschemicalwearbecomesaleadingwearmechanismandoftenacceleratesweakeningofcuttingedge,resultinginprematuretoolfailure(chipping),namelyedgebreakageofthecuttingtool.Inaddition,Thieleetal.[24]noticedthatwhenfeedrateisincreased,residualstresseschangefromcompressivetotensile.
1.4Surfaceintegrity,residualstressesandtoolwear
Ingeneral,residualstressesbecomemorecompressiveasworkpiecehardnessincreases.ThehardnessandfracturetoughnessofCBNtoolsdecreasewithreducedCBNcontent[8].Owingtoceramicbinderphase,CBN-Ltoolshavealowerthermalconductivity,whichcausesincreasingtemperaturesofcuttingedgeduringhardturning.ChouandBarash[9]reportedthatCBN-Ltoolsaremoresuitableforfinishturningofhardenedsteel.Atlowcuttingspeeds,toollifeofCBN-LissuperiortoCBN-H,whereasathighercuttingspeeds,thereverseistrue,andalsosurfaceroughnessislessfavorablewhenusingCBN-Htool[28].Thieleetal.[24]reportedthatresidualstressesgeneratedbylargeedgehonetoolsaretypicallymorecompressivethanstressesproducedbysmalledgehonetoolsandtheyalsoleavewhite-layers.Inaddition,theeffectsofedgegeometryplayanimportantroleinthermoplasticdeformationoftheworkpiece.Koenigetal.[3]reportedthatanincreaseinfeedrateraisesthecompressiveresidualstressmaximalanddeepenstheaffectedzone.Itwasalsosuggestedthatthechamferisunfavorableintermsofattainablesurfacefinishwhencomparedtohonedorsharpedges.
1.5Accuracyandrigidityofthemachinetool
Anotherparameterthatisoftenignoredistoolvibration.Inordertoreducetoolvibrationitisnecessaryprovidesufficientlyrigidtoolandworkpiecefixtures.Assuringthatthereisminimaltoolvibrationisaneasywaytoimprovesurfaceroughness.Itisalsonecessarythatthetoolingsystembeextremelyrigidtowithstandtheimmensecuttingforces.Itiswellknownthattheradialforceisthelargestamongforcecomponentsduringhardturning.Manyresearchersindicatedthatextremelyrigid,highpower,andhighprecisionmachinetoolsarerequiredforhardturningbecauseCBNtoolsarebrittleandpronetochipping[3,7,8,14,23].Itisalsosuggestedthathavinghigherrigidityinmachinetool-clamping-toolingsystemachievesbettersurfacequalityonthepart.Itiswellknownthatvibrationandchatterareimportantproblemsthatdegradepartqualityandtoolperformance.
Toimprovetheoverallefficiencyoffinishhardturning,itisnecessarytohaveacompleteprocessunderstanding.Tothisend,agreatdealofresearchhasbeenperformedinordertoquantifytheeffectofvarioushardturningprocessparameterstosurfacequality.Inordertogainagreaterunderstandingofthehardturningprocessitisnecessarytounderstandtheimpactofeachofthesevariables,butalsotheinteractionsbetweenthem.Itisimpossibletofindallofthevariablesthatimpactsurfacequalityinfinishhardturning.Inaddition,itiscostlyandtime-consumingtodiscerntheeffectofeveryvariableontheoutput.
2.EXPERIMENTALPROCEDURE
2.1Workpiecematerial
TheworkpiecematerialusedinthisstudywasAISIH13hotworktoolsteel,whichisusedforhighdemandtooling.ThecylindricalbarAISIH13specimenthatareutilizedinthisexperimentshadadiameterof1.25inchesandlengthof2feet.Thebarspecimenswereheattreated(through-hardened)atin-househeattreatmentfacilityinordertoobtainthedesiredhardnessvaluesof
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