Abstract
To analyze hard turning performance characteristics, a new mathematical model was developed for the hard turning process, and cutting force (CF), another important response for cutting machining, was also studied in the present work. The analysis of the mathematical model and experimental results revealed that thrust force (Fy) was the largest, followed by tangential force (Fz) and feed force (Fx). The resultant CF was most influenced by inclination angle (IA) with 25.02%, followed by rake angle (RA) (14.26%) and cutting edge angle (CEA) (10.04%). Increasing CEA changed the position of cutting on the tool-nose radius and increased local negative RA and correspondingly local clearance angle (CA). Meanwhile, increasing negative RA and IA resulted in larger local negative RA and CA. Moreover, local RA and local CA were the main geometric factors affecting surface roughness (SR), tool wear (TW), and CF. Increasing local negative RA resulted in higher SR and CF. In contrast, increasing local CA resulted in lower SR, TW, and CF. Under specific conditions, the positive effects of the local CA overcame the negative effects of the local negative RA, leading to a simultaneous decrease in SR and TW. The proposed novel mathematical model can be further applied to calculate local CF, cutting temperature, and TW for each cutting-edge element, to analyze and optimize the hard turning process.
Highlights
Hard turning is an advanced technology to machine hard materials and has many advantages compared to conventional grinding
Saglam et al studied the effect of feed rate, cutting edge angle (CEA), and rake angle (RA) on cutting force (CF) components and cutting temperature in hard turning of AISI 1040 hardened steel by uncoated cemented carbide tool [8]. e authors found that higher CEA produced lower thrust force and higher feed force, and increasing the positive RA decreased CF and increased the cutting temperature
Sharma et al found that surface roughness (SR) increases with feed rate but decreases with CEA, cutting speed and cutting depth when hard turning with coated carbide insert [11]. is means that the influences of CEA on SR in the studies of Neseli et al and Sharma et al were opposite, indicating that the influences of the tool geometry on conventional turning were different from the influences on hard turning
Summary
Hard turning is an advanced technology to machine hard materials and has many advantages compared to conventional grinding. Harisha et al used the Taguchi approach for experimental design and optimization of machining parameters, including CEA, cutting depth, feed rate, and tool nose radius to minimize CF when turning AISI 1055 hardened steel [7]. Singh and Rao investigated the influence of tool geometries, including nose radius and effective rake angle (RA), and machining parameters, including feed rate and cutting speed on SR when hard turning AISI 52100 steel with mixed ceramic inserts [9]. Suresh and Basavarajappa studied the effect of machining parameters (depth of cut, cutting speed, and feed rate) on TW and SR in hard turning AISI H13 steel (55 HRC) by coated ceramic inserts [17]. CF, another important response for cutting machining, was studied in the present work, and we proposed a new geometrical model to explain the effects of tool angle parameters on performance characteristics of hard turning, including SR, TW, and CF
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