1
Effect on cutting forcein turning hardened tool
steelswith cubic boron nitride inserts.
Authors Mohammad Robiul Hossan Li Qian
Journal of Materials Processing Technology Volume
191, Issues 1-3, 1 August 2007, Pages 274-278

• Stuart McAllister
• October 10, 2007

2
Introduction

• A performance comparison of turning various
  hardened steels with CBN inserts is not available
  in literature.
• FEA results in terms of forces are presented for
  orthogonal high-speed machining of
• AISI 52100 hardened bearing steel
• AISI H13 hot work tool steel
• AISI D2 cold work steel
• AISI 4340 low alloy steel

3
Introduction

• The following effects on forces were
  investigated
• Cutting speed
• Feed
• Cutter Geometry
• Workpiece hardness
• FEA results were compared with the experimental
  results reported in the referenced literature.

4
Models Design Principles

• AdvantEdge software used
• To perform numerical simulations with FEA
• 2D Lagrangian FEA modeling software
• Models created
• FEA model
• Machining process model
• Material properties model
• Friction model
• Detailed information on models in Ref. 10

5
Models Design Principles

• Fig. 1 shows the schematic of orthogonal cutting
  conditions used for the 2D finite element mesh.
• The cutting tool is characterized by rake angle,
  relief angle, and cutting edge radius.
• The process parameters include feed f, cutting
  speed V, and depth of cut (doc).

(Fig. 1.) 
6
Models Design Principles

• Table 1. material properties, heat treat process,
  application

Material UTS YS E Heat Treat Process Application
H13 1990 1650 210 Quench, annealing, stress relieving Die casting dies
52100 1640 1230 210 Quenched, harden Bearings
D2 2940 2200 210 Harden Gages, long-run dies
4340 1300 1200 210 Quench, temper General application

7
Models Design Principles

• Table 2. Cutting process parameters in numerical
  simulations

Workpiece hardness 44, 48, 52, 58 HRC
Workpiece material AISI 52100, D2, H13, AISI 4340
Tool insert CBN
Depth of cut (mm) 0.2
Feed (mm) 0.15, 0.3, 0.45, 0.6
Cutting speed (m/min) 140, 180, 240
Rake angle () -5, -15, -25
Edge radius (mm) 0.02, 0.06, 0.1, 0.2
Relief angle () 6
8
Results

• Data on cutting forces is essential
• For minimizing distortion of machine components,
  workpiece, fixture, and cutters.
• For selecting a machine and machine tool with
  adequate power.
• Forces arising from orthogonal cutting
• Cutting Force in direction of cutting speed
• Feed Force normal to cutting speed

9
Results

• Forces do not change much with cutting speed
  within the recommended cutting speed range.

Fig. 2. Effect of CS and workpiece material on
cutting force.
Fig. 3. Effect of CS and workpiece material on
feed force.
10
Results

• Feed has the most significant effect on cutting
  and feed forces.
• Forces increase with the increase in feed due to
  an increase in chip load.

Fig. 4. Effect of feed and material on cutting
force.
Fig. 5. Effect of feed and material on feed
force.
11
Results

• Force increase as tool radius increases.
• Forces increase as rake angle decreases.

Fig. 7. Effect of rake angle and tool material on
cutting force.
Fig. 6. Effect of tool edge radius and tool
material on cutting force.
12
Results

• Force increases as hardness increases.
• Forces increase as depth of cut increases.

Fig. 9. Effect of depth of cut on forces.
Fig. 8. Effect of hardness and tool material on
cutting force.
13
Conclusions

• Predicted cutting forces agree with available
  literature data with reasonable accuracy.
• Cutting force and feed force increase with
  increasing feed, tool edge radius, negative rake
  angle, and workpiece hardness.
• Feed force is a larger force component than
  cutting force in hard turning.
• Consistent with experimental and numerical
  results of other researchers.

14
Conclusions

• Under same turning conditions
• AISI 4340 highest cutting force
• AISAS 52100 highest feed force
• AISI D2 lowest cutting and feed forces
• Further work should include
• More experimental runs to verify conclusions
• Investigating temperature, shear angle, chip
  geometry, shear stress, plastic strain rate
• Using 3D FEA model simulations

15
Conclusions

• Industrial Use?
• A performance comparison of turning hardened
  steels with CBN inserts now available.
• Technical Advancement?
• No, but more information on hard turning
  available.
• Industries impacted?
• Those that perform hard machining with CBN
  inserts will have more data available to them.

16
References

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