In this study, 3-D finite element modeling of precision hard turning has been used to investigate the effects of cutting edge microgeometry on tool forces, temperatures and stresses in machining of AISI H13 steel using polycrystalline cubic boron nitrite (PCBN) inserts with two distinct edge preparations. Hard turning experiments were conducted to investigate the effects of cutting edge geometr...

Original scientific paper In this paper, the orthogonal cutting force model is proposed comprising forces due to flank wear in addition to the forces for chip formation during the hard turning of round bar made of steel 60WCrV7 hardened at 55+2HRc. Cutting force model includes two tool conditions: perfectly sharp tool with VBB = 0 and tool with maximum permissible flank wear VBBmax. Based on cu...

A novel fractal estimation methodology, that uses—for the first time in metal cutting literature—fractal properties of machining dynamics for online estimation of cutting tool flank wear, is presented. The fractal dimensions of the attractor of machining dynamics are extracted from a collection of sensor signals using a suite of signal processing methods comprising wavelet representation and si...

ABSTRACT Inconel 718 is a difficult-to-cut nickel-based superalloy commonly used in aerospace industry. This paper presents an experimental study of the tool wear propagation and cutting force variations in the end milling of Inconel 718 with coated carbide inserts. The experimental results showed that significant flank wear was the predominant failure mode affecting the tool life. The tool fla...

The current experimental study is to investigate the effects of process parameters (cutting speed, feed rate and depth of cut) on performance characteristics (surface roughness, machining force and flank wear) in hard turning of AISI 4340 steel with multilayer CVD (TiN/TiCN/Al2O3) coated carbide insert. Combined effects of cutting parameter (v, f, d) on performance outputs (Ra, Fm and VB) ar...

We report the development of a predictive model based on artificial neural network (ANN) for the estimation of flank and nose wear of uncoated carbide inserts during orthogonal turning of NST (Nigerian steel) 37.2. Turning experiments were conducted at different cutting conditions on a M300 Harrison lathe using Sandvic Coromant uncoated carbide inserts with ISO designations SNMA 120406 using fu...

Metal deposition at the tool flank wear-land during machining is a common phenomenon, especially in machining aluminum alloys and annealed teels. The cause of metal deposit has not been studied and the characteristics of the wear-land and deposit contact are not completely known. In his study, a turning test was conducted using tungsten carbide (WC) tools with pre-generated wear-land to machine...

Metal matrix composites have been widely used in industries, especially aerospace industries, due to their excellent engineering properties. However, it is difficult to machine them because of the hardness and abrasive nature of reinforcement elements like silicon carbide particles (SiCp).In the present study, an attempt has been made to investigate the influence of spindle speed (N), feed rate...

The cutting tools are today used a lot by industry and they are expensive, so it was interesting to optimize their use, by developing a predictive method of their wear, particularly, the flank wear Vb. For this task, the flank tool wear was measured in off-line using a binocular microscope, whereas, the cutting forces are recorded by means of a dynamometer (Kistler 9255B). The acquired signatur...

Productivity and quality in the finish turning of hardened steels can be improved by utilizing predicted performance of the cutting tools. This paper combines predictive machining approach with neural network modeling of tool flank wear in order to estimate performance of chamfered and honed Cubic Boron Nitride (CBN) tools for a variety of cutting conditions. Experimental work has been performe...