Abstract
High-speed machining (HSM) is used in industry to improve the productivity and quality of the cutting operations. In this investigation, pure alumina ceramics with the addition of ZrO2, and mixed alumina (Al2O3 + TiC) tools were used in the dry hard turning of AISI 4340 (52 HRC) at different high cutting speeds of 150, 250, 700 and 1000 m/min. It was observed that at cutting speeds of 150 and 250 m/min, pure alumina ceramic tools had better wear resistance than mixed alumina ones. However, upon increasing the cutting speed from 700 to 1000 m/min, mixed alumina ceramic tools outperformed pure ceramic ones. Scanning electron microscopy (SEM) and X-ray photoelectron spectroscopy (XPS) were used to investigate the worn cutting edges and analyze the obtained results. It was found that the tribo-films formed at the cutting zone during machining affected the wear resistances of the tools and influenced the coefficient of friction at the tool-chip interface. These observations were confirmed by the chip compression ratio results at different cutting conditions. Raising cutting speed to 1000 m/min corresponded to a remarkable decrease in cutting force components in the dry hard turning of AISI 4340 steel.
Highlights
High-speed machining (HSM) is used in different industrial applications, including the machining of molds, dies, and superalloys [1]
Due to the relatively high cutting forces produced during cutting of hardened materials [23], determination of these forces is essential for not exceeding the elastic limit of the Machine-Fixture-Tool-Workpiece (MFTW) system [24]
X-ray photoelectron spectroscopy (XPS) analysis carried out on the worn area of the pure alumina ceramic tool at 250 m/min showed the formation of a protective alumina tribo-film with sapphire crystal structure as well as a ZrO2 tribo-film that decreased the coefficient of friction at the tool-chip interface
Summary
High-speed machining (HSM) is used in different industrial applications, including the machining of molds, dies, and superalloys [1]. The use of cutting tools with a predictable performance is an essential factor in undertaking a successful high-speed machining operation. Flank wear can be considered to be mechanically driven wear resulting from the abrasion of the hard particles inside the workpiece material with the cutting tools [8].
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