Abstract
Performance of cutting tool in hard turning is significantly influenced by its microgeometry, such as edge radius. This study presents an experimental exploration to understand the effect of cutting edge radius on machining performance in terms of surface roughness and tool wear. The cutting tools (CBN) with three groups of nominal edge radius, 20, 30, and 40 μm, were used in the study. The cutting edge radii were characterized with an Alicona optical microscope, and variation of the edge radius was evaluated in this study. The machining tests were then conducted to experimentally assess the effect of cutting edge radius on surface quality and tool wear under different machining conditions. Three-level and two-factor experiments were designed in the test. The results in this study suggest that there is noticeable variation in the edge radius on a cutting tool with a certain nominal value of edge radius. The variations tend to be smaller with increase of the nominal value of edge radius. Besides, the results can be drawn that edge radii have a significant influence on surface roughness and tool wear. Considering all factors, the cutting tool with nominal edge radius of 30 μm demonstrate better machining performance among three groups of cutting tool in hard turning of AISI52100 steel.
Highlights
As hard turning can offer attractive advantages in terms of higher material removal rate, shorter setup time, and reduced production cost, it has become a potential substitute for conventional grinding
Workpiece hardness is usually higher than 45 hardness–Rockwell C (HRC) and a cutting tool is often subjected to extremely high local mechanical and thermal stresses, which can cause chipping and wear on the edge of the cutting tool and thereby influence the cutting force, tool wear, chip formation, surface integrity, and accuracy of machining
In the investigation conducted by Chou et al [2], the surface roughness was found to be strongly influenced by tool nose radius and tool wear, and the results manifested that large tool nose radius can obtain finer surface finish, but it increases tool wear
Summary
As hard turning can offer attractive advantages in terms of higher material removal rate, shorter setup time, and reduced production cost, it has become a potential substitute for conventional grinding. Workpiece hardness is usually higher than 45 hardness–Rockwell C (HRC) and a cutting tool is often subjected to extremely high local mechanical and thermal stresses, which can cause chipping and wear on the edge of the cutting tool and thereby influence the cutting force, tool wear, chip formation, surface integrity, and accuracy of machining. Cutting tool geometry, especially microgeometry, such as edge radius and chamfer (length and angle) plays an important role in the performance of the cutting tool during the hard turning processes. Many investigations have been conducted to explore the effect of cutting tool geometry on the surface integrity, cutting force, and tool life in hard turning. A large difference was found in the tool life when the chamfer angle changes from 10° to
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