Study on physical and technological effects of precise turning with self-propelled rotary tool

Abstract

This study is focused on some physical and technological aspects of a precise turning with Self-Propelled Rotary Tool (SPRT). As part of experiment, the cutting forces, on-line insert run-out and machined surface topography were investigated. Turning tests were carried in the range of variable feeds, depths of cut and cutting speeds for a hardened 41Cr4 steel with the use of a coated carbide round indexable inserts. The effect of cutting conditions on the tool rotation and the dynamics of cutting force signal were evaluated. In particular, changes of cutting forces vs. cutting lengths for different cutting parameters were analyzed in terms of the cutting insert rotation, and Power Spectral Density (PSD) analysis. Moreover, the original method based on cutting force oscillations was employed to estimate the on-line insert run-out. Ultimately, the analysis of a machined surface topography was conducted, considering the interactions between the process inputs and outputs. It was shown that application of high cutting speeds and feeds during SPRT turning can lead to the improvements in surface finish, as well as the stabilization of cutting force values.