共查询到20条相似文献,搜索用时 15 毫秒
1.
Samir Khamel Nouredine Ouelaa Khaider Bouacha 《Journal of Mechanical Science and Technology》2012,26(11):3605-3616
The main of the present study is to investigate the effects of process parameters (cutting speed, feed rate and depth of cut) on performance characteristics (tool life, surface roughness and cutting forces) in finish hard turning of AISI 52100 bearing steel with CBN tool. The cutting forces and surface roughness are measured at the end of useful tool life. The combined effects of the process parameters on performance characteristics are investigated using ANOVA. The composite desirability optimization technique associated with the RSM quadratic models is used as multi-objective optimization approach. The results show that feed rate and cutting speed strongly influence surface roughness and tool life. However, the depth of cut exhibits maximum influence on cutting forces. The proposed experimental and statistical approaches bring reliable methodologies to model, to optimize and to improve the hard turning process. They can be extended efficiently to study other machining processes. 相似文献
2.
J. M. Zhou M. Andersson J. E. Stahl 《The International Journal of Advanced Manufacturing Technology》2003,22(9-10):697-702
In precision hard turning, tool flank wear is one of the major factors contributing to the geometric error and thermal damage in a machined workpiece. Tool wear not only directly reduces the part geometry accuracy but also increases the cutting forces drastically. The change in cutting forces causes instability in the tool motion, and in turn, more inaccuracy. There are demands for reliably monitoring the progress of tool wear during a machining process to provide information for both correction of geometric errors and to guarantee the surface integrity of the workpiece. A new method for tool wear monitoring in precision hard turning is presented in this paper. The flank wear of a CBN tool is monitored by feature parameters extracted from the measured passive force, by the use of a force dynamometer. The feature parameters include the passive force level, the frequency energy and the accumulated cutting time. An ANN model was used to integrate these feature parameters in order to obtain more reliable and robust flank wear monitoring. Finally, the results from validation tests indicate that the developed monitoring system is robust and consistent for tool wear monitoring in precision hard turning. 相似文献
3.
4.
Analysis of surface roughness and cutting force components in hard turning with CBN tool: Prediction model and cutting conditions optimization 总被引:1,自引:0,他引:1
Hamdi Aouici Mohamed Athmane YalleseKamel Chaoui Tarek MabroukiJean-François Rigal 《Measurement》2012,45(3):344-353
In this study, the effects of cutting speed, feed rate, workpiece hardness and depth of cut on surface roughness and cutting force components in the hard turning were experimentally investigated. AISI H11 steel was hardened to (40; 45 and 50) HRC, machined using cubic boron nitride (CBN 7020 from Sandvik Company) which is essentially made of 57% CBN and 35% TiCN. Four-factor (cutting speed, feed rate, hardness and depth of cut) and three-level fractional experiment designs completed with a statistical analysis of variance (ANOVA) were performed. Mathematical models for surface roughness and cutting force components were developed using the response surface methodology (RSM). Results show that the cutting force components are influenced principally by the depth of cut and workpiece hardness; on the other hand, both feed rate and workpiece hardness have statistical significance on surface roughness. Finally, the ranges for best cutting conditions are proposed for serial industrial production. 相似文献
5.
Yong Huang Y. Kevin Chou Steven Y. Liang 《The International Journal of Advanced Manufacturing Technology》2007,35(5-6):443-453
Direct machining steel parts at a hardened state, known as hard turning, offers a number of potential benefits over traditional
grinding in some applications. In addition, hard turning has several unique process characteristics, e.g., segmented chip
formation and microstructural alterations at the machined surfaces, fundamentally different from conventional turning. Hard
turning is, therefore, of a great interest to both the manufacturing industry and research community. Development of superhard
materials such as polycrystalline cubic boron nitride (known as CBN) has been a key to enabling hard turning technology. A
significant pool of CBN tool wear studies has been surveyed, in an attempt to achieve better processing and tooling applications,
and discussed from the tool wear pattern and mechanism perspectives. Although various tool wear mechanisms, or a combination
of several, coexist and dominate in CBN turning of hardened steels, it has been suggested that abrasion, adhesion (possibly
complicated by tribochemical interactions), and diffusion may primarily govern the CBN tool wear in hard turning. Further,
wear rate modeling including one approach developed in a recent study, on both crater and flank wear, is discussed as well.
In conclusion, a summary of the CBN tool wear survey and the future work are outlined. 相似文献
6.
Mohammad Usman Ghani Nuri A. Abukhshim M. A. Sheikh 《The International Journal of Advanced Manufacturing Technology》2008,39(9-10):874-888
This paper presents results of an investigation into the tool life and the tool wear behaviour of low content CBN cutting tools used in hard turning of hardened H13 tool steel. The approach followed here required both experimental work and finite element thermal modelling. The experiments involved measuring the cutting forces, cutting temperatures, tool wear, and the contact area. Using the measured cutting forces and the contact area in the orthogonal cutting model, we calculated the heat flux on the tool and applied it in the FE thermal analysis. The temperatures history from the analysis was matched with the experimental data to estimate the fraction of heat entering the tool for both conventional and high speeds. The heat partition into the tool was estimated to be around 21–22% for conventional speeds, whereas for high-speed turning, it was around 14%. The tool wear, however, was found to be dominated by chipping for both cutting speeds and could be reduced considerably by reducing the amount of heat entering the tool. 相似文献
7.
Influence of tool wear on surface roughness in hard turning using differently shaped ceramic tools 总被引:3,自引:0,他引:3
Hard turning has been applied in many cases in producing bearings, gears, cams, shafts, axels, and other mechanical components since the early 1980s. Mixed ceramics (aluminum oxide plus TiC or TiCN) is one of the two cutting tool materials (apart from PCBN) widely used for finish machining of hardened steel (HRC 50–65) parts, especially under dry machining conditions and moderate cutting speed ranging from 90 to 120 m/min. This paper reports an extensive characterization of the surface roughness generated during hard turning (HT) operations performed with conventional and wiper ceramic tools at variable feed rate and its changes originated from tool wear. Moreover, it compares some predominant tool wear patterns produced on the two types of ceramic inserts and their influence on the alteration of surface profiles. After the hard turning tests, the relevant changes of surface profiles and surface roughness parameters were successively registered and measured by a stylus profilometer. In this investigation, a set of 2D surface roughness parameters, as well as profile and surface characteristics, such as the amplitude distribution functions, bearing area curves and symmetrical curves of geometrical contact obtained for the machined surface, were determined and analyzed. A novel aspect of this research is that the notch wear progress at the secondary cutting (trailing) edges was found to produce the substantial modifications of the individual irregularities, and constitute the altered surface profiles. Moreover, this research contributes to practical aspects of HT technology due to exploring the relations between the tool state at different times within the tool life and the relevant surface roughness characterization. 相似文献
8.
H.A. Kishawy Lei Pang M. Balazinski 《International Journal of Mechanical Sciences》2011,53(11):1015-1021
In this paper, an attempt is made to evaluate the self-propelled rotary carbide tool performance during machining hardened steel. Although several models were developed and used to evaluate the tool wear in conventional tools, there were no attempts in open literature for modeling the progress of tool wear when using the self-propelled rotary tools. Flank wear model for self-propelled rotary cutting tools is developed based on the work-tool geometric interaction and the empirical function. A set of cutting tests were carried out on the AISI 4340 steel with hardness of 54–56 HRC under different cutting speeds and feeds. The progress of tool wear was recorded under different interval of time. A genetic algorithm was developed to identify the constants in the proposed model. The comparison of measured and predicted flank wear showed that the developed model is capable of predicting the rate of rotary tool flank wear progression. 相似文献
9.
T. Tamizharasan T. Selvaraj A. Noorul Haq 《The International Journal of Advanced Manufacturing Technology》2006,28(7-8):671-679
Hard turning is a profitable alternative to finish grinding. The ultimate aim of hard turning is to remove work piece material
in a single cut rather than a lengthy grinding operation in order to reduce processing time, production cost, surface roughness,
and setup time, and to remain competitive. In recent years, interrupted hard turning, which is the process of turning hardened
parts with areas of interrupted surfaces, has also been encouraged. The process of hard turning offers many potential benefits
compared to the conventional grinding operation. Additionally, tool wear, tool life, quality of surface turned, and amount
of material removed are also predicted. In this analysis, 18 different machining conditions, with three different grades of
polycrystalline cubic boron nitride (PCBN), cutting tool are considered. This paper describes the various characteristics
in terms of component quality, tool life, tool wear, effects of individual parameters on tool life and material removal, and
economics of operation. The newer solution, a hard turning operation, is performed on a lathe. In this study, the PCBN tool
inserts are used with a WIDAX PT GNR 2525 M16 tool holder. The hardened material selected for hard turning is commercially
available engine crank pin material. 相似文献
10.
11.
On the prediction of surface roughness in the hard turning based on cutting parameters and tool vibrations 总被引:1,自引:0,他引:1
Zahia Hessainia Ahmed Belbah Mohamed Athmane Yallese Tarek Mabrouki Jean-François Rigal 《Measurement》2013
This research work concerns the elaboration of a surface roughness model in the case of hard turning by exploiting the response surface methodology (RSM). The main input parameters of this model are the cutting parameters such as cutting speed, feed rate, depth of cut and tool vibration in radial and in main cutting force directions. The machined material tested is the 42CrMo4 hardened steel by Al2O3/TiC mixed ceramic cutting tool under different conditions. The model is able to predict surface roughness of Ra and Rt using an experimental data when machining steels. The combined effects of cutting parameters and tool vibration on surface roughness were investigated while employing the analysis of variance (ANOVA). The quadratic model of RSM associated with response optimization technique and composite desirability was used to find optimum values of cutting parameters and tool vibration with respect to announced objectives which are the prediction of surface roughness. The adequacy of the model was verified when plotting the residuals values. The results indicate that the feed rate is the dominant factor affecting the surface roughness, whereas vibrations on both pre-cited directions have a low effect on it. Moreover, a good agreement was observed between the predicted and the experimental surface roughness. Optimal cutting condition and tool vibrations leading to the minimum surface roughness were highlighted. 相似文献
12.
13.
Tool wear, chip formation and workpiece surface issues in CBN hard turning: A review 总被引:1,自引:0,他引:1
Manu Dogra Vishal S. Sharma Anish Sachdeva Narinder Mohan Suri Jasminder Singh Dureja 《International Journal of Precision Engineering and Manufacturing》2010,11(2):341-358
Steel parts that carry critical loads in everything from automotive drive trains and jet engines to industrial bearings and
metal-forming machinery are normally produced by a series of processes, including time-consuming and costly grinding and polishing
operations. Due to the advent of super-hard materials such as polycrystalline cubic boron nitride (PCBN) cutting tools and
improved machine tool designs, hard turning has become an attractive alternative to grinding for steel parts. The potential
of hard turning to eliminate the costs associated with additional finishing processes in conventional machining is appealing
to industry. The objective of this paper, is to survey the recent research progress in hard turning with CBN tools in regard
of tool wear, surface issues and chip formation. A significant pool of CBN turning studies has been surveyed in an attempt
to achieve better understanding of tool wear, chip formation, surface finish, white layer formation, micro-hardness variation
and residual stress on the basis of varying CBN content, binder, tool edge geometry, cooling methods and cutting parameters.
Further important modeling techniques based on finite element, soft computing and other mathematical approaches used in CBN
turning are reviewed. In conclusion, a summary of the CBN turning and modeling techniques is outlined and the scope of future
work is presented. 相似文献
14.
Influence of minimum quantity lubrication parameters on tool wear and surface roughness in milling of forged steel 总被引:1,自引:0,他引:1
The minimum quantity of lubrication (MQL) technique is becoming increasingly more popular due to the safety of environment.Moreover,MQL technique not only leads to economical benefits by way of saving ... 相似文献
15.
Xiaobin Cui Jun Zhao Yongwang Dong 《The International Journal of Advanced Manufacturing Technology》2013,66(5-8):955-964
High-speed face milling of AISI H13 hardened steel is conducted in order to investigate the effects of cutting parameters on tool life and wear mechanisms of the cubic boron nitride (CBN) tools. Cutting speeds ranging from 400 to 1,600 m/min are selected. For each cutting speed, the metal removal rate and axial depth of cut are fixed, and different combinations of radial depth of cut and feed per tooth are adopted. The tool life, tool wear progression, and tool wear mechanisms are analyzed for different combinations of cutting parameters. It is found that for most of the selected cutting speeds, the tool life increases with radial depth cut and then decreases. For each cutting speed, the CBN tool life can be enhanced by means of adopting suitable combination of cutting parameters. When the cutting speed increases, the normal wear stage becomes shorter and the tool wear rate grows larger. Because of the variations of cutting force and tool temperature, the tool wear mechanisms change with different combinations of cutting parameters even at the same cutting speed. At relatively low cutting speed, in order to acquire high tool life of the CBN tool, the tool material should possess sufficient capability of resisting adhesion from the workpiece. When relatively high cutting speed is adopted, retention of mechanical properties to high cutting temperature and resistance to mechanical impact are crucial for the enhancement of the CBN tool life. 相似文献
16.
《机械工程学报(英文版)》2019,32(6)
Ball burnishing is a plastic deformation process used as a surface smoothing and surface improvement finishing treatment after turning or milling processes. This process changes the surface stereometrics of the previously machining surface. Burnishing with hydrostatic tools can be easily and effectively used on both conventional and Computer Numeric Control(CNC) machines. The existing research of the burnishing process mainly focuses on the functional surface characterization, for example, surface roughness, wear resistance, surface layer hardness, etc. There is a lack of references reporting a detailed analysis of 3D parameters calculation with a mathematical model to evaluate the results of the ball burnishing. This paper presents the effect of ball burnishing process parameters with hydrostatic tools on the resulting surface structure geometry. The surface topography parameters were calculated using the Taly Map software. Studies were conducted based on Hartley's static, determined plan. Such a plan can be built on a hypersphere or hypercube. In this work, a hypercube was used. In the case of Hartley's plan makes it possible to define the regression equation in the form of a polynomial of the second degree. The input process parameters considered in this study include the burnishing rate, applied pressure, and line-to-line pitch. The significant influence of these parameters was confirmed and described as a mathematical power model. The results also showed a positive effect of hydrostatic burnishing on the roughness and geometric structure of the surface. 相似文献
17.
Nayak Rupak Kumar Bartarya Gaurav Sahoo Manas Ranjan 《Journal of Mechanical Science and Technology》2021,35(3):1215-1222
Journal of Mechanical Science and Technology - The white layer formed during hard turning deteriorates surface integrity, thereby severely affecting the fatigue life of machined parts. A 2D... 相似文献
18.
《Measurement》2016
In this work, the cutting parameters are optimized in hard turning of ADI using carbide inserts based on Taguchi method. The cutting insert CVD coated with AL2O3/MT TICN. Experiments have been carried out in dry condition using L18 orthogonal array. The cutting parameters selected for machining are cutting speed, feed rate and depth of cut with each three levels, nose radius in two levels maintaining other cutting parameters constant. The ANOVA and signal to noise ratio are used to optimize the cutting parameters. The cutting speed is the most dominant factor affecting the surface roughness and tool wear. In optimum cutting condition, the confirmation tests are carried out. The optimum cutting condition results are predicted using signal to noise ratio and regression analysis. The predicted and experimental values for surface roughness and tool wear adhere closer to 9.27% and 1.05% of deviations respectively. 相似文献
19.
《计算机集成制造系统》2015,(11)
为了实现车削加工过程的低碳化并提高加工质量,在分析车削加工过程中能耗特征及切削温度与刀具几何参数之间关系的基础上,以刀具前角和主偏角为优化变量,考虑加工过程机床设备和加工质量等约束,建立了车削加工刀具几何参数低碳优化模型;针对所建模型,提出一种基于改进的自适应遗传算法的优化求解方法。实例分析表明,以低碳排放为优化目标、以切削温度为约束条件优化车削刀具几何参数,可使碳排放和切削温度比原刀具参数分别降低12%和17%。所建模型和方法可为制造企业优化选择刀具几何参数降低碳排放提供理论方法支持。 相似文献
20.
Sanjeev Saini Inderpreet Singh Ahuja Vishal S. Sharma 《The International Journal of Advanced Manufacturing Technology》2013,65(5-8):667-678
In the present study, an attempt has been made to model the effect of cutting parameters (cutting speed, feed, depth of cut and nose radius) on residual stresses in hard turning of AISI H11 tool steel using ceramic tools. The machining experiments were conducted based on response surface methodology and using the Box–Behnken design of experiments. Residual stresses were determined using the X-ray diffraction technique, and the experimental results were investigated using analysis of variance. The results indicated that the feed and depth of cut are the main influencing factor on residual stresses whereas cutting speed and nose radius are having mild impact on residual stresses. The results show that it is possible to produce tailor-made residual stress levels by controlling the tool geometry and cutting parameters. The aim of this paper is to introduce an original approach for the prediction of residual stresses. 相似文献