Abstract
Surface roughness is an important factor in metal cutting, and usually different surface roughness characteristics are used to control the quality of the machined surfaces. However, as the cutting tool wears out during the cutting process, the roughness values change. In most cases, theoretical roughness values are calculated without taking the wear characteristics of the tool into account. For this reason, the calculated and measured roughness values may differ from each other, and the tendency of their change may also be different. This paper presents a method for the determination of the theoretical roughness of hard turned surfaces considering the wear of the cutting tool. The purpose of the analyses performed was to show the effect of wear trace on the tool and the roughness of the machined surface and to give a possible method to take the wear into account when calculating the theoretical roughness values. During the investigations, the shape of the actual (worn) edge section of the cutting tool was recorded by an optical microscope, and the theoretical surface roughness values were calculated with that profile by a CAD modeling method developed earlier. Cutting experiments were conducted on a lathe machine with two similar cutting tools, one of them has significant tool wear, while the other was a completely new one. The calculated theoretical roughness values were compared with real measured roughness values, and the error of the estimates was between 8.7 and 68.3%, larger errors were found at lower feeds.
Highlights
Hard turning is a widely used process to cut the surfaces of hard materials that have hardness values over 45 HRC
The surface roughness in hard turning is relatively easy to estimate, as the process is performed with a single point cutting tool having definite edge geometry [14]
A new method was introduced in the paper for the determination of theoretical roughness valuef,sminmturning processes
Summary
Hard turning is a widely used process to cut the surfaces of hard materials that have hardness values over 45 HRC. This process is especially important in the manufacturing of automotive parts [1] alongside other industry segments, e.g., marine [2], aerospace [3], punch and die or mold making [4], among others. The surface roughness in hard turning is relatively easy to estimate, as the process is performed with a single point cutting tool having definite edge geometry (i.e., the exact form of the cutting edge is known, and its lengths and angles are exactly defined in contrast with abrasive processes, where the edge geometry is not defined) [14]. Some of the works considered more important by the authors are presented
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