Characterization of Surface Integrity Produced by Sequential Dry Hard Turning and Ball Burnishing Operations

2014 ◽  
Vol 136 (3) ◽  
Author(s):  
Wit Grzesik ◽  
Krzysztof Żak
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Hard Turning ◽  
Cubic Boron Nitride ◽  
High Strength ◽  
Lower Surface ◽  
Roughness Parameters ◽  
Ball Burnishing ◽  
Machining Processes ◽  
Finish Hard Turning

This paper presents the state of surface integrity produced on hardened-high strength 41Cr4 steel after hard machining and finish ball burnishing. Surfaces machined by sequential machining processes were characterized using 2D and 3D surface roughness parameters. Moreover, detailed functionality of the generated surfaces was performed using a set of 3D functional roughness parameters. Among the characteristics of the surface layer, its microstructure, the distribution of microhardness and the residual stresses were determined. This investigation confirms that ball burnishing allows producing surfaces with lower surface roughness and better service properties than those generated by cubic boron nitride (CBN) finish hard turning operations.

scholarly journals Surface Integrity and Corrosion Resistance of 42CrMo4 High-Strength Steel Strengthened by Hard Turning

Materials ◽  
2021 ◽  
Vol 14 (22) ◽  
pp. 6995
Author(s):  
Qingzhong Xu ◽  
Yan Liu ◽  
Haiyang Lu ◽  
Jichen Liu ◽  
Gangjun Cai
Keyword(s):  
Surface Roughness ◽  
Corrosion Resistance ◽  
Compressive Stress ◽  
Surface Integrity ◽  
High Strength Steel ◽  
Hard Turning ◽  
High Strength ◽  
Residual Compressive Stress ◽  
Surface Microhardness ◽  
Surface Corrosion

To improve the surface corrosion resistance of 42CrMo4 high-strength steel used in a marine environment, this article studied the effects of hard turning on the surface integrity and corrosion resistance of 42CrMo4 high-strength steel through the single factor experimental method, namely hard turning, polarization corrosion, electrochemical impedance spectroscopy, potentiodynamic polarization curve, and salt spray tests. The results indicated that the surface integrity was modified by the hard turning, with a surface roughness lower than Ra 0.8 μm, decreased surface microhardness, fine and uniform surface microstructure, and dominant surface residual compressive stress. The hard turning process was feasible to strengthen the surface corrosion resistance of 42CrMo4 high-strength steel. The better corrosion resistance of the surface layer than that of the substrate material can be ascribed to the uniform carbides and compact microstructure. The corrosion resistance varied with cutting speeds as a result of the changed surface microhardness and residual compressive stress, varied with feed rates as a result of the changed surface roughness, and varied with cutting depths as a result of the changed surface residual compressive stress, respectively. The surface integrity with smaller surface roughness and microhardness and bigger surface residual compressive stress was beneficial for corrosion resistance.

Effects of Tool Geometry and Workpiece Hardness on Surface Roughness in Finish Hard Turning of AISI 440C

2010 ◽  
Vol 97-101 ◽  
pp. 1815-1818
Author(s):  
Zhen Yu Shi ◽  
Zhan Qiang Liu
Keyword(s):  
Surface Roughness ◽  
Flow Stress ◽  
Hard Turning ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Surface Hardness ◽  
Lower Surface ◽  
Tool Geometry ◽  
Workpiece Surface ◽  
Finish Hard Turning

In this study, the effects of cutting tool geometry and workpiece hardness on surface roughness in finish hard turning of AISI 440C steel were experimental investigated. Four-factor (hardness, tool geometry, feed rate and cutting speed) two-level fractional experiments were conducted and analysis of variance (ANOVA) was performed. This study showed that the effects of workpiece hardness and tool geometry on surface roughness are statistically significant. Especially lower workpiece surface hardness and larger tool nose angle resulted in lower surface roughness because that the surface hardness influences the workpiece’s flow stress and the tool nose angle changes the contact area between the cutting tool and workpiece.

Analysis on Finish Hard Turning of Ti-6.5Al-3.5Mo-1.5Zr-0.3Si Alloy

2009 ◽  
Vol 626-627 ◽  
pp. 225-230 ◽  
Author(s):  
Wei Wei Ming ◽  
Ming Chen ◽  
Bin Rong
Keyword(s):  
Corrosion Resistance ◽  
Elevated Temperature ◽  
Tool Wear ◽  
Hard Turning ◽  
Density Ratio ◽  
High Strength ◽  
Excellent Performance ◽  
Good Corrosion Resistance ◽  
Tool Wear Mechanism ◽  
Finish Hard Turning

Titanium alloys are extensively applied in aerospace, automotive, biomedical, and chemical industries owing to their excellent performance combining high strength-to-density ratio, good corrosion resistance, and high strength at elevated temperature. Ti-6.5Al-3.5Mo-1.5Zr-0.3Si (TC11) alloys are used to replace the most common Ti-6Al-4V in some important applications such as some parts in aerospace engine. The purpose of this paper is to evaluate the machinability of TC11 alloys in the finish hard turning conditions. The paper presents the machinability results of TC11 alloys compared with Ti-6Al-4V, and analyzes the variables such as cutting force, surface integrity, and tool wear mechanism in the experiments.

scholarly journals Cutting Mechanics and Surface Finish for Turning with Differently Shaped CBN Tools

2017 ◽  
Vol 64 (3) ◽  
pp. 347-357
Author(s):  
Krzysztof Żak
Keyword(s):  
Surface Roughness ◽  
Hard Turning ◽  
Cutting Parameters ◽  
Material Distribution ◽  
Roughness Parameters ◽  
Turning Operations ◽  
Cutting Power ◽  
Finish Turning ◽  
Corner Radius ◽  
Relevant Material

Abstract In this paper, the basic cutting characteristics such as cutting forces, cutting power and its distribution, specific cutting energies were determined taking into account variable tool corner radius ranging from 400 to 1200 µm and constant cutting parameters typical for hard turning of a hardened 41Cr4 alloy steel of 55±1 HRC hardness. Finish turning operations were performed using chamfered CBN tools. Moreover, selected roughness profiles produced for different tool corner radius were compared and appropriate surface roughness parameters were measured. The measured values of Ra and Rz roughness parameters are compared with their theoretical values and relevant material distribution curves and bearing parameters are presented.

Effect of Workpiece Hardness on Surface Microgeometry when Hard Turning with Ceramic Inserts

2013 ◽  
Vol 581 ◽  
pp. 176-181 ◽  
Author(s):  
Ildikó Maňková ◽  
Jozef Beňo ◽  
Marek Vrabel'
Keyword(s):  
Surface Roughness ◽  
Hard Turning ◽  
Surface Profile ◽  
Surface Finishing ◽  
Oxide Ceramic ◽  
Part Surface ◽  
Cutting Force Components ◽  
Finish Hard Turning ◽  
Force Components ◽  
Mixed Ceramic

Hard turning provides an alternative to grinding in some finishing operations. This paper deals with analysis of part surface finishing when turning hardened steel heat-treated on hardness of 46, 55 and 60 HRC with mixed oxide ceramic inserts. Average surface roughness Ra has been widely used in industry it is known that the single parameter Ra is inadequate to define the functionality of a surface. Two different surfaces with similar values of Ra can behave differently under loading conditions. The surface profile 2D and 3D parameters are assessed. The influence of workpiece hardness on surface roughness parameters and cutting force components is investigated. Results show that finish hard turning with mixed ceramic tool produces surface profile comparable to those produced by grinding.

Влияние условий шлифования на магнитный отклик инструментальной стали AISI D2

2021 ◽  
Vol 3 ◽  
pp. 26-36
Author(s):  
Ашвани Шарма ◽  
Абхиманью Чаудхари ◽  
Акаш Субхаш Авале ◽  
Мохд Захир Хан Юсуфзай ◽  
Меганшу Вашиста
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Ground Surface ◽  
Qualitative Evaluation ◽  
Lower Surface ◽  
Barkhausen Noise ◽  
Softening Effect ◽  
Ground Sample ◽  
High Productivity ◽  
Aisi D2

Nowadays, precision manufacturing industries are required faster surface inspection tools for the achievement of high productivity. In this context, the Barkhausen noise (BN) technique is adopted as a quick response technique in the grinding for qualitative evaluation of surface integrity of AISI D2 tool steel. Present work investigates the effect of eco-friendly coolant, i.e., cryogenic, on surface integrity of ground sample in the plunge grinding mode at different downfeed and compared with dry and wet environments. Surface integrity was assessed in respect of surface roughness, microstructure, and microhardness. Magnetic response of ground surface was reported by Barkhausen noise analyzer in the form of root mean square (rms), peak, and number of pulses. From the outcomes, it was perceived that no significant variations were found in the microstructure and microhardness of the ground surface and subsurface after cryo-grinding owing to lower thermo-mechanical loading. Besides, lower surface roughness was obtained in the case of cryo-grinding because of thermal softening effect. A linear correlation between BN input parameters, i.e., magnetic field intensity and BN responses at different magnetizing frequency could be achieved. Finally, better BN responses, including higher rms, peak, and number of pulses, were found under the cryogenic environment.

Mikrofräswerkzeuge mit Schneiden aus cBN*/Micro-cutting tools with cBN cutters

2018 ◽  
Vol 108 (11-12) ◽  
pp. 773-777
Author(s):  
E. Uhlmann ◽  
J. Polte ◽  
M. Polte ◽  
Y. Kuche ◽  
H. Wiesner
Keyword(s):  
Surface Roughness ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
High Strength ◽  
Hardened Steel ◽  
Micro Milling ◽  
Geometric Accuracy ◽  
Micro Cutting ◽  
Core Technology ◽  
Milling Tools

Die Mikrozerspanung ist eine Kerntechnologie bei der Fertigung von Mikrospritzgussformen. Die hohen Ansprüche an die geometrische Genauigkeit und Oberflächenrauheit erfordern den Einsatz hochfester Werkstoffe. Jedoch unterliegen aktuelle Fräswerkzeuge bei der Mikrozerspanung einem hohen Verschleiß. Einen Lösungsansatz bietet der erfolgreich in der Makrozerspanung eingesetzte Schneidstoff kubisch-kristallines Bornitrid (cBN). Ziel der Untersuchungen war es daher, detaillierte Informationen zur Bearbeitung von gehärtetem Stahl mit cBN-Mikrofräswerkzeugen bereitstellen zu können.   Micro-cutting is a core technology for producing micro-injection moulds. High demands on geometric accuracy and surface roughness require high-strength materials. However, current milling tools for micro-cutting suffer from excessiv tool wear. A solution is offered by cutting materials based on cubic Boron Nitride (cBN), which have been used successfully in macro-machining. This article contains detailed information on the machining of hardened steel with micro-milling tools and cutting edges made of cBN.

Comparison of surface integrity of Ti6Al4V titanium alloy manufactured by laser deposition and traditional method after end milling

2020 ◽  
pp. 095440622097213
Author(s):  
Ben Wang ◽  
Qi Zhang ◽  
Minghai Wang ◽  
Yaohui Zheng ◽  
Xianjun Kong
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Surface Integrity ◽  
Work Hardening ◽  
End Milling ◽  
Orthogonal Experiment ◽  
High Strength ◽  
Laser Deposition ◽  
Ti Alloy ◽  
Ti6al4v Titanium Alloy

Ti alloy has been widely applied in aerospace due to its high strength, good corrosion resistance, and excellent high-temperature performances. The quality and usability of Ti alloy parts are closely related to surface integrity. In this study, a comparative analysis of the milling surface integrity between laser deposition manufacturing and traditional Ti6Al4V samples was conducted. End milling surfaces of additive and traditional Ti6Al4V samples were observed with an orthogonal experiment under different milling parameters from the perspectives of cutting force, surface morphology, surface roughness, subsurface damages, and microhardness. Results demonstrate that the additive Ti6Al4V sample has a slightly higher cutting force and surface roughness relative to traditional Ti6Al4V. This is related to the higher hardness and plasticity of the additive Ti6Al4V sample. There are unmelted powder particle defects on the milling surface of the additive Ti6Al4V sample and serious cracking defects on the subsurface of the additive Ti6Al4V sample. The microhardness of the work hardening layer and base of the additive Ti6Al4V sample is higher than that of traditional Ti6Al4V. Moreover, the additive Ti6Al4V sample presents higher work hardening and a larger depth of the hardening layer. These findings demonstrate that material properties and manufacturing processes can influence surface integrity significantly.

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