Abstract
This paper describes an experimental and theoretical investigation of the AISI D2 hardened steel. The hardened material (over 60 HRc) is machined using CBN tools with different radii to obtain chips of various sizes for different cutting conditions. The tool geometry was set at −7 and a 45 approach angle was used. The cutting performance was measured by taking into account the cutting forces, chip thicknesses, shear angle and the secondary deformation zones. In addition, a theoretical model is developed by taking into account the flow stress properties of the AISI D2 steel available in the literature for use with the Oxley machining approach. A comparison of the predicted and experimental results indicates good agreement.
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