Abstract
In the intermittent machining of hardened steel for the die and mold industry, determining how to reduce the wear of PCBN (Polycrystalline Cubic Boron Nitride) tools and improve their machining efficiency and quality is an important subject. This study investigated the intermittent machining of hardened steel (Cr12MoV, 59HRC (Rockwell hardness)) using uncoated PCBN tools to determine the cutting performance (cutting force, chip morphology, surface quality, tool life, cutting temperature) and the wear/damage characteristics of the tools. The results showed that the cutting performance of a PCBN tool was better than that of a cemented carbide tool. The wear mechanism on the PCBN tool flank was diffusion wear, adhesive wear, and oxidation wear. The main failure modes of the PCBN tool in the machining process of hardened steel at low speed were tool micro-chipping, the conchoidal damage of the rake face, and the larger damaged area of the flank face. The main failure modes of the PCBN tool in the machining process of hardened steel at high speed were flank wear and high-rate fatigue damage.
Highlights
PCBN is a cutting tool material most widely used in the machining of hardened steel due to its higher hardness, strength, thermal and chemical stability, and thermal conductivity, and lower friction coefficient than other tool materials at high temperature [1,2,3]
The results indicated that the PCBN tool gave excellent performance in terms of tool life and surface finish in comparison with carbide-coated tools
The cutting performances and the wear/damage characteristics of PCBN tools were investigated for the intermittent machining of hardened steel
Summary
PCBN is a cutting tool material most widely used in the machining of hardened steel due to its higher hardness, strength, thermal and chemical stability, and thermal conductivity, and lower friction coefficient than other tool materials at high temperature [1,2,3]. The main wear mechanism of PCBN tools in continuous and intermittent cutting of hardened steel (1117 steel, HRC62+1) was abrasive wear [13]. The main wear mechanism of PCBN tools in intermittent turning of bearing steel (AISIE-52100, HRC60) was abrasive wear and adhesion wear [14]. Okada et al [21] studied the cutting force, cutting temperature, tool wear, and surface roughness of PCBN tools with different CBN content in hard milling hardened steel. Saketi et al [25] investigated the wear properties of PCBN tool with high CBN content in milling hardened steel. The cutting performances (cutting force, chip morphology, surface quality, tool life, cutting temperature) and the wear/damage characteristics of PCBN tools were investigated for the intermittent machining of hardened steel
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