Tool wear effects on white and dark layer formation in hard turning of AISI 52100 steel

Abstract In the present investigation a series of orthogonal hard turning tests were conducted to study the effects of tool wear and cutting parameters (cutting speed and feed rate), on white and dark layer formation in hardened AISI 52100 bearing steel, using PCBN inserts. Experimental results were presented including quantification of tool wear and microstructure analysis of the machined surfaces. The experimental results were compared with a newly developed finite elements (FE) model that enables to capture the effect of cutting conditions and tool wear on the microstructural changes occurring at the machined surface. The results showed that cutting regime parameters and, especially, tool wear affect noticeably white and dark layers formation.

[1]  Shreyes N. Melkote,et al.  Analysis of white layers formed in hard turning of AISI 52100 steel , 2005 .

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

[3]  Shreyes N. Melkote,et al.  Effect of finishing methods on surface characteristics and performance of precision components in rolling/sliding contact , 2009 .

[4]  Liam Blunt,et al.  White Layers on Surface of Ground EN24 Steel: 1Microstructure, Composition, Internal Stress, and Corrosion Properties , 1989 .

[5]  Luigino Filice,et al.  Improving surface integrity in orthogonal machining of hardened AISI 52100 steel by modeling white and dark layers formation , 2009 .

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

[7]  Domenico Umbrello,et al.  Influence of material microstructure changes on surface integrity in hard machining of AISI 52100 steel , 2011 .

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

[9]  Ekkard Brinksmeier,et al.  Capability Profile of Hard Cutting and Grinding Processes , 2005 .

[10]  Wanci Shen,et al.  Microstructures of surface white layer and internal white adiabatic shear band , 1997 .

[11]  A. W. Warren,et al.  Surface Integrity Difference between Hard Turned and Ground Surfaces and Its Impact on Fatigue Life , 2006 .

[12]  I. S. Jawahir,et al.  MODELING OF WHITE AND DARK LAYER FORMATION IN HARD MACHINING OF AISI 52100 BEARING STEEL , 2010 .

[14]  Shreyes N. Melkote,et al.  Modeling of white layer formation under thermally dominant conditions in orthogonal machining of hardened AISI 52100 steel , 2008 .

[15]  Yuebin Guo,et al.  A comparative study of hard turned and cylindrically ground white layers , 2004 .

[16]  Hossam A. Kishawy,et al.  Surface Integrity of Die Material in High Speed Hard Machining, Part 1: Micrographical Analysis , 2000 .

[17]  Srinivasan Chandrasekar,et al.  Formation of white layers in steels by machining and their characteristics , 2002 .

[18]  Gerry Byrne,et al.  TEM study on the surface white layer in two turned hardened steels , 2002 .

[19]  Christopher J. Evans,et al.  White Layers and Thermal Modeling of Hard Turned Surfaces , 1997, Manufacturing Science and Engineering: Volume 2.

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

[21]  Shreyes N. Melkote,et al.  Effect of surface integrity of hard turned AISI 52100 steel on fatigue performance , 2007 .

[22]  D. Umbrello,et al.  Hardness-based flow stress and fracture models for numerical simulation of hard machining AISI 52100 bearing steel , 2004 .

[23]  M. C. Shaw,et al.  Heat-Affected Zones in Grinding Steel , 1994 .