Evolution of tool flank wear and its influence on machining characteristics in pressurized-oil jet assisted hard turning
Keywords:Hard turning, Coated carbide tool, Wear evolution, Surface roughness, High-pressure coolant
Machining of hardened steels (? 40 HRC) is claimed as difficult due to excessive tool wear, increased machined surface roughness and high temperature. High-pressure coolant (HPC) jet, applied as an effective cooling/lubricating mode, is expected to reduce the difficulty in machining of hardened steel. To this aim, in this study, CVD multi-layer coated (TiCN/Al2O3/TiN) WC inserts are examined after machining of steels hardened at ~40 HRC, ~48 HRC and ~56 HRC at cutting speed of 90 m/min, feed rate of 0.12 mm/rev and cutting depth of 2.0 mm at dry as well as HPC jet condition. HPC jet was impinged at chip-tool interface to attain efficacious penetration. After 20 minutes of machining, the tool flank wears were studied using both wear measurement and scanning electron microscopic (SEM) imagery; moreover, average surface roughness (Ra) was plotted to correlate with tool flank wear; lastly, the chips were studied. From the results found eminent tool wear mechanisms are abrasion, adhesion, and built-up-edge. It is further evident, turning of ~56 HRC steel in dry condition is not possible owing to tool failure whereas HPC corroborates failure-free turning. Attained benefits by HPC may be accredited to a reduced contact of chip-tool, chip uplifting by jet wedge, lubrication, and cooling.
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