Comparison of tool life between ceramic and cubic boron nitride (CBN) cutting tools when machining hardened steels

Abstract This paper describes a comparison of tool life between ceramics and cubic boron nitride (CBN) cutting tools when machining hardened bearing steels using the Taguchi method. An orthogonal design, signal-to-noise ratio (S/N) and analysis of variance (ANOVA) were employed to determine the effective cutting parameters on the tool life. First order linear and exponential models were carried out to find out the correlation between cutting time and independent variables. Second order regression model was also extended from the first order model when considering the effect of cutting speed (V), feed rate (f), hardness of cutting tool (TH) and two-way of interactions amongst V, f, TH variables. The results indicated that the V was found to be a dominant factor on the tool life, followed by the TH, lastly the f. The CBN cutting tool showed the best performance than that of ceramic based cutting tool. In addition, optimal testing parameter for cutting times was determined. The confirmation of experiment was conducted to verify the optimal testing parameter. Furthermore, the second order regression model and exponential model supported the first order model regarding the prediction capability. Improvements of the S/N ratio from initial testing parameters to optimal cutting parameters or prediction capability depended on the S/N ratio and ANOVA results. Moreover, the ANOVA indicated that the cutting speed was a higher significant but other parameters were also significant effects on the tool lives at 90% confidence level. The percentage contributions of the cutting speed, tool’s hardness, and feed rate were about 41.63, 32.68, and 25.22 on the tool life, respectively.

[1]  Ty G. Dawson,et al.  Tool crater wear depth modeling in CBN hard turning , 2005 .

[2]  Yunn-Shiuan Liao,et al.  Wear characteristics in turning high hardness alloy steel by ceramic and CBN tools , 1999 .

[3]  Y. K. Chou,et al.  Tool nose radius effects on finish hard turning , 2004 .

[4]  Tuğrul Özel,et al.  Prediction of flank wear by using back propagation neural network modeling when cutting hardened H-13 steel with chamfered and honed CBN tools , 2002 .

[5]  J. Paulo Davim,et al.  A note on the determination of optimal cutting conditions for surface finish obtained in turning using design of experiments , 2001 .

[6]  Anselmo Eduardo Diniz,et al.  Hard turning of interrupted surfaces using CBN tools , 2008 .

[7]  S. K. Choudhury,et al.  Role of temperature and surface finish in predicting tool wear using neural network and design of experiments , 2003 .

[8]  Shreyes N. Melkote,et al.  Effect of Cutting-Edge Geometry and Workpiece Hardness on Surface Residual Stresses in Finish Hard Turning of AISI 52100 Steel , 1999, Manufacturing Science and Engineering.

[9]  Maan Aabid Tawfiq,et al.  A Finite Element Analysis of Orthogonal Machining Using Different Tool Edge Geometries , 2007, Engineering and Technology Journal.

[10]  Fritz Klocke,et al.  Development of a tool wear-monitoring system for hard turning , 2003 .

[11]  H. Chandrasekaran,et al.  Investigation of the effects of tool micro-geometry and coating on tool temperature during orthogonal turning of quenched and tempered steel , 2004 .

[12]  A. Senthil Kumar,et al.  Machinability of hardened steel using alumina based ceramic cutting tools , 2003 .

[13]  J. A. Arsecularatnea,et al.  Wear and tool life of tungsten carbide , PCBN and PCD cutting tools , 2006 .

[14]  Tuğrul Özel,et al.  Predictive modeling of surface roughness and tool wear in hard turning using regression and neural networks , 2005 .

[15]  P. C. Jindal,et al.  Performance of PVD TiN, TiCN, and TiAlN coated cemented carbide tools in turning , 1999 .

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

[17]  Margaret J. Robertson,et al.  Design and Analysis of Experiments , 2006, Handbook of statistics.

[18]  Hocheng Hong,et al.  Comparison of the tool life of tungsten carbides coated by multi-layer TiCN and TiAlCN for end mills using the Taguchi method , 2002 .

[19]  J. Paulo Davim,et al.  Investigations into the effect of cutting conditions on surface roughness in turning of free machining steel by ANN models , 2008 .

[20]  Ali Riza Motorcu,et al.  Surface roughness model in machining hardened steel with cubic boron nitride cutting tool , 2008 .

[21]  Xiaowen Wang,et al.  Development of Empirical Models for Surface Roughness Prediction in Finish Turning , 2002 .

[22]  Gerry Byrne,et al.  Cutting tool wear in the machining of hardened steels , 2001 .

[23]  Uday S. Dixit,et al.  Prediction of surface roughness and dimensional deviation by measuring cutting forces and vibrations in turning process , 2003 .

[24]  Fukuo Hashimoto,et al.  Effect of feed rate, workpiece hardness and cutting edge on subsurface residual stress in the hard turning of bearing steel using chamfer + hone cutting edge geometry , 2005 .

[25]  Chuanzhen Huang,et al.  Mechanical property and cutting performance of yttrium-reinforced Al2O3/Ti(C,N) composite ceramic tool material , 2001 .

[26]  Gérard Poulachon,et al.  Wear behavior of CBN tools while turning various hardened steels , 2004 .

[27]  Y. S. Tarng,et al.  Design optimization of cutting parameters for turning operations based on the Taguchi method , 1998 .

[28]  Hossam A. Kishawy,et al.  Tool wear and surface integrity during high-speed turning of hardened steel with polycrystalline cubic boron nitride tools , 2001 .

[29]  W. Grzesik,et al.  Surface finish generated in hard turning of quenched alloy steel parts using conventional and wiper ceramic inserts , 2006 .

[30]  Bernhard Sick,et al.  ON-LINE AND INDIRECT TOOL WEAR MONITORING IN TURNING WITH ARTIFICIAL NEURAL NETWORKS: A REVIEW OF MORE THAN A DECADE OF RESEARCH , 2002 .

[31]  Janez Kopac,et al.  Optimal machining parameters for achieving the desired surface roughness in fine turning of cold pre-formed steel workpieces , 2002 .

[32]  Abdulrahman Al-Ahmari,et al.  Predictive machinability models for a selected hard material in turning operations , 2007 .

[33]  S. Khrais,et al.  Wear mechanisms and tool performance of TiAlN PVD coated inserts during machining of AISI 4140 steel , 2007 .

[34]  Che Hassan Che Haron,et al.  Wear of coated and uncoated carbides in turning tool steel , 2001 .

[35]  Suhas S. Joshi,et al.  Effect of machining parameters and cutting edge geometry on surface integrity of high-speed turned Inconel 718 , 2008 .

[36]  A. Abrão,et al.  Hard turning: AISI 4340 high strength low alloy steel and AISI D2 cold work tool steel , 2005 .

[37]  Ossama B. Abouelatta,et al.  Surface roughness prediction based on cutting parameters and tool vibrations in turning operations , 2001 .

[38]  J. Paulo Davim,et al.  Machinability evaluation in hard turning of cold work tool steel (D2) with ceramic tools using statistical techniques , 2007 .

[39]  Ya-Tsun Hsiao,et al.  Use of Ceramic Tools in Hard Turning of Hardened AISI M2 Steel , 2000 .

[40]  Gérard Poulachon,et al.  An experimental investigation of work material microstructure effects on white layer formation in PCBN hard turning , 2005 .

[41]  Y. Şahin.  The effects of various multilayer ceramic coatings on the wear of carbide cutting tools when machining metal matrix composites , 2005 .

[43]  I. Jawahir,et al.  Tool-wear mechanisms in hard turning with polycrystalline cubic boron nitride tools , 2001 .

[44]  S. Lim,et al.  Work material and the effectiveness of coated tools , 2001 .

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

[46]  Alexandre M. Abrão,et al.  The effect of cutting fluids on the machining of hardened AISI 4340 steel , 2001 .

[47]  A. Senthil Kumar,et al.  Wear behaviour of alumina based ceramic cutting tools on machining steels , 2006 .

[48]  A. Abrão,et al.  Turning of hardened 100Cr6 bearing steel with ceramic and PCBN cutting tools , 2003 .