Presentation on theme: "Stuart McAllister October 10, 2007"— Presentation transcript:
1 Stuart McAllister October 10, 2007 “Effect on cutting force in turning hardened tool steels with cubic boron nitride inserts.”Authors: Mohammad Robiul Hossan & Li QianJournal of Materials Processing TechnologyVolume 191, Issues 1-3, 1 August 2007, PagesStuart McAllisterOctober 10, 2007
2 IntroductionA performance comparison of turning various hardened steels with CBN inserts is not available in literature.FEA results in terms of forces are presented for orthogonal high-speed machining of:AISI hardened bearing steelAISI H13 hot work tool steelAISI D2 cold work steelAISI 4340 low alloy steel
3 Introduction The following effects on forces were investigated: Cutting speedFeedCutter GeometryWorkpiece hardnessFEA results were compared with the experimental results reported in the referenced literature.
4 Models & Design Principles AdvantEdge software used:To perform numerical simulations with FEA2D Lagrangian FEA modeling softwareModels created:FEA modelMachining process modelMaterial properties modelFriction modelDetailed information on models in Ref. 
5 Models & Design Principles Fig. 1 shows the schematic of orthogonal cutting conditions used for the 2D finite element mesh.The cutting tool is characterized by rake angle, relief angle, and cutting edge radius.The process parameters include feed f, cutting speed V, and depth of cut (doc).(Fig. 1.)
8 Results Data on cutting forces is essential: For minimizing distortion of machine components, workpiece, fixture, and cutters.For selecting a machine and machine tool with adequate power.Forces arising from orthogonal cutting:Cutting Force – in direction of cutting speedFeed Force – normal to cutting speed
9 ResultsForces do not change much with cutting speed within the recommended cutting speed range.Fig. 2. Effect of CS and workpiece material on cutting force.Fig. 3. Effect of CS and workpiece material on feed force.
10 ResultsFeed has the most significant effect on cutting and feed forces.Forces increase with the increase in feed due to an increase in chip load.Fig. 4. Effect of feed and material on cutting force.Fig. 5. Effect of feed and material on feed force.
11 Results Force increase as tool radius increases. Forces increase as rake angle decreases.Fig. 7. Effect of rake angle and tool material on cutting force.Fig. 6. Effect of tool edge radius and tool material on cutting force.
12 Results Force increases as hardness increases. Forces increase as depth of cut increases.Fig. 8. Effect of hardness and tool material on cutting force.Fig. 9. Effect of depth of cut on forces.
13 ConclusionsPredicted cutting forces agree with available literature data with reasonable accuracy.Cutting force and feed force increase with increasing feed, tool edge radius, negative rake angle, and workpiece hardness.Feed force is a larger force component than cutting force in hard turning.Consistent with experimental and numerical results of other researchers.
14 Conclusions Under same turning conditions: AISI 4340 highest cutting forceAISAS highest feed forceAISI D2 lowest cutting and feed forcesFurther work should include:More experimental runs to verify conclusionsInvestigating temperature, shear angle, chip geometry, shear stress, plastic strain rateUsing 3D FEA model simulations
15 Conclusions Industrial Use? Technical Advancement? A performance comparison of turning hardened steels with CBN inserts now available.Technical Advancement?No, but more information on hard turning available.Industries impacted?Those that perform hard machining with CBN inserts will have more data available to them.
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