Modeling of CBN Tool Flank Wear Progression in Finish Hard Turning

Cubic Boron Nitride (CBN) cutters are widely used in finish turning of hardened parts. Their wear mechanisms and associated wear rates are important issues to be understood in view of the high cost of CBN cutters and because of the tool change down-time cost which impacts the economic justification of CBN precision hard turning. The objective of this study is to present a methodology to analytically model the CBN tool flank wear rate as a function of tool/workpiece material properties, cutting parameters and process arrangement in three-dimensional finish hard turning. The proposed model is calibrated with experimental data of finish turning of hardened 52100 bearing steel with a CBN insert, and further validated over practical hard turning conditions. It is shown that adhesion is the main wear mechanism over common cutting conditions, which agrees with documented observations, however, chemical diffusion can gain dominance over extended periods of machining time under aggressive cutting conditions.

[1]  S. Liang,et al.  Modelling of the cutting temperature distribution under the tool flank wear effect , 2003 .

[2]  W. König,et al.  Wear mechanisms of ultrahard, non-metallic cutting materials , 1993 .

[3]  R. Komanduri,et al.  Machining of Hard Materials , 1984 .

[4]  Patrick Judd,et al.  Computational design of wear coatings , 1985 .

[5]  Matthew A. Davies,et al.  On Chip Morphology, Tool Wear and Cutting Mechanics in Finish Hard Turning , 1996 .

[6]  S. A. Klimenko,et al.  On the wear mechanism of cubic boron nitride base cutting tools , 1992 .

[7]  Gerry Byrne,et al.  Cutting tool wear in the machining of hardened steels: Part I: alumina/TiC cutting tool wear , 2001 .

[8]  Patrick Kwon,et al.  Predictive models for flank wear on coated inserts , 2000 .

[9]  Y. K. Chou,et al.  Experimental investigation on CBN turning of hardened AISI 52100 steel , 2002 .

[10]  Steven Y. Liang,et al.  Modeling of Cutting Forces Under Hard Turning Conditions Considering Tool Wear Effect , 2005 .

[11]  W. König,et al.  ON THE WEAR OF CUTTING TOOLS , 1968 .

[12]  N. H. Cook,et al.  Tool Wear and Tool Life , 1973 .

[13]  M. C. Shaw,et al.  Mechanics of Machining: An Analytical Approach to Assessing Machinability , 1989 .

[14]  Ty G. Dawson,et al.  Machining hardened steel with polycrystalline cubic boron nitride cutting tools , 2002 .

[15]  B. Kramer,et al.  Predicted wear resistances of binary carbide coatings , 1986 .

[16]  R. M. Hooper,et al.  Microstructure and wear of TiC-cubic BN tools , 1988 .

[17]  J. Archard.  Contact and Rubbing of Flat Surfaces , 1953 .

[18]  Hans Kurt Tönshoff,et al.  Cutting of Hardened Steel , 2000 .

[19]  Jiří Tlustý,et al.  Manufacturing processes and equipment , 1999 .

[20]  Y. Chou,et al.  Wear mechanisms of cubic boron nitride tools in precision turning of hardened steels , 1994 .

[21]  Steven Y. Liang,et al.  Cutting forces modeling considering the effect of tool thermal property—application to CBN hard turning , 2003 .

[22]  Thomas Childs,et al.  Metal Machining: Theory and Applications , 2000 .

[23]  T. Kitagawa,et al.  Analytical Prediction of Three Dimensional Cutting Process—Part 3: Cutting Temperature and Crater Wear of Carbide Tool , 1978 .

[24]  E. Kannatey-Asibu.  A Transport-Diffusion Equation in Metal Cutting and its Application to Analysis of the Rate of Flank Wear , 1985 .

[25]  Taylan Altan,et al.  Process modeling in machining. Part I: determination of flow stress data , 2001 .

[26]  T. N. Loladze.  Of the Theory of Diffusion Wear , 1981 .

[27]  E. Rabinowicz,et al.  A study of abrasive wear under three-body conditions , 1961 .