Modification of the Tool-Workpiece Contact Conditions to Influence the Tool Wear and Workpiece Loading During Hard Turning
Berend Denkena, Jens Köhler, Roland Meyer,
and Jan-Hendrik Stiffel
Institute of Production Engineering and Machine Tools (IFW), Leibniz Universität Hannover, An der Universität 2, Garbsen 30826, Germany
Tool wear during hard machining leads to unfavourable changes in the workpiece surface and subsurface layers. Due to increasing flank wear, thermal and mechanical loads affect the microstructure and the residual stress state of the workpiece subsurface. These effects cause a reduction in the lifetime of the machined components during operation. This article presents an approach of modified corner radii of cutting tools for hard turning processes to change the tool wear progression and the influence on the machined subsurface layers. Hereby the size and direction of the contact length of the cutting edge is adjusted as well as the specific load during machining. The results show the potential of controlling the tool wear and the workpiece subsurface properties by the contact conditions of the tool-workpiece interface during hard turning.
-  S. Kukino, K. Okamura, S. Uesaka, and T. Fukaya, “High Efficiency and High Surface Integrity Machining of Hardened Steel with New PCBN Tools,” Proc. of the 2nd Int. Industrial Diamond Conf., Rome, 2007.
-  F. Klocke, E. Brinksmeier, and K. Weinert, “Capability Profile of Hard Cutting and Grinding Processes,” Annals of the CIRP, 54 (2), pp. 557-580, 2005.
-  H.Weisser, “In Grosserie Hartdrehen statt Schleifen,” Werkstatt und Betrieb, 127 (5), pp. 320-322, 1994.
-  B. Sieben, T. Wagner, and D. Biermann, “Empirical modeling of hard turning of AISI 6150 steel using design and analysis of computer experiments,” Prod. Eng. Res. Dev., 2010.
-  H. Tönshoff, C. Arendt, and R. B. Amor, “Cutting of Hardened Steel, Annals of the CIRP, 49 (2), pp. 547-566, 2000.
-  A. W. Warren and Y. B. Guo, “Characteristics of Residual Stress Profiles in Hard Turned Versus Ground Surfaces With and Without a White Layer,” J. of Manufacturing Science and Engineering, Vol. 131, pp. 041004/1-10, 2009.
-  J. D. Thiele and S. N. Melkote, “Effect of Tool Edge Geometry on Workpiece Subsurface Deformation and Through-Thickness Residual Stresses for Hard turning of AISI 52100 Steel,” J. of Manufacturing Processes, Vol.2, No.4, 2000.
-  M. Field and J. Kahles, “Review of surface integrity of machined components,” Annals of the CIRP, Band 20, pp. 153-163, 1971.
-  D. Brandt, “Randzonenbeeinflussung beim Hartdrehen,” Dissertation Universität Hannover, 1995.
-  P. Vomacka and H. Walburger, “Residual stresses due to hardmachining industrial experiences,” in Proc. of the 5th European Conf. on Residual stresses, Switzerland, pp. 592-597, 2000.
-  L. De León Garcia, “Residual stress and part distortion in milled aerospace aluminium,” Dr.-Ing. Dissertation, Leibniz Universität Hannover, 2010.
-  E. Brinksmeier, M. Garbrecht, D. Meyer, and J. Dong, “Surface hardening by strain induced martensitic transformation,” Prod. Eng. Res. Dev. 2, pp. 109-1216, 2008.
-  B. Denkena, D. Boehnke, and R. Meyer, “Reduction of wear induced surface zone effects during hard turning by means of new tool geometries,” Prod. Eng. Res. Dev. 2, pp. 123-132, 2008.
-  B. Denkena, L. de Leon, R. Meyer, and M. Otte, “Verringerung der Randzonenbeeinflussung beim Hartdrehen durch neue Werkzeuggeometrien,” VDI-Z Special Werkzeug-/Formenbau, 150 III, pp. 27-30, 2008.
-  S. Jochmann, “ Untersuchungen zur Prozessauslegung beim Hochpräzisionshartdrehen,” Dissertation, Rheinisch-Westfälische Techn. Hochschule Aachen, 2001.