High-speed machining of martensitic stainless steel using PcBN
The performance of PcBN cutting tool during its application in the mass production of components made from AISI 440B stainless steel has been considered. The experimental tests have been performed at cutting speed ranging between 350–500 m/min at dry cutting conditions. The machining operations that...
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Інститут надтвердих матеріалів ім. В.М. Бакуля НАН України
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irk-123456789-1311742018-03-15T03:02:56Z High-speed machining of martensitic stainless steel using PcBN Sobiyi, K. Sigalas, I. Получение, структура, свойства The performance of PcBN cutting tool during its application in the mass production of components made from AISI 440B stainless steel has been considered. The experimental tests have been performed at cutting speed ranging between 350–500 m/min at dry cutting conditions. The machining operations that have been explored included facing, turning, grooving and boring and the 3D topography of the machined surface presented. The results show that good surface finish similar to grinding and dimensional accuracy can be achieved with PcBN tools. Рассмотрены рабочие характеристики режущего инструмента, оснащенного поликристаллическим кубическим нитридом бора (КНБ), используемого в массовом производстве изделий из нержавеющей стали AISI 440B. Экспериментальные испытания проводили при скорости резания в диапазоне от 350 до 500 м/мин в условиях сухого резания. Представлены операции обработки, включающие обточку торца, точение, прорезание канавок и сверление, а также 3D-топография обработанной поверхности. Результаты показывают, что, применяя в инструментах поликристаллический КНБ, можно достичь хорошего качества обработки поверхности и точности размеров, таких же как при шлифовании. Розглянуто робочі характеристики ріжучого інструменту, оснащеного полікристалічним кубічним нітридом бору (КНБ), що використовують в масовому виробництві виробів з нержавіючої сталі AISI 440B. Експериментальні випробування проводили при швидкості різання в діапазоні від 350 до 500 м/хв в умовах сухого різання. Представлено операції обробки, що включають обточування торця, точіння, прорізання канавок і свердління, а також 3D-топографія обробленої поверхні. Результати показують, що, застосовуючи в інструментах полікристалічний КНБ, можна досягти хорошої якості обробки поверхні і точності розмірів, таких же як при шліфуванні. 2016 Article High-speed machining of martensitic stainless steel using PcBN / K. Sobiyi, I. Sigalas // Сверхтвердые материалы. — 2016. — № 1. — С. 45-51. — Бібліогр.: 16 назв. — англ. 0203-3119 http://dspace.nbuv.gov.ua/handle/123456789/131174 21.9.01 en Сверхтвердые материалы Інститут надтвердих матеріалів ім. В.М. Бакуля НАН України |
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Получение, структура, свойства Получение, структура, свойства |
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Получение, структура, свойства Получение, структура, свойства Sobiyi, K. Sigalas, I. High-speed machining of martensitic stainless steel using PcBN Сверхтвердые материалы |
| description |
The performance of PcBN cutting tool during its application in the mass production of components made from AISI 440B stainless steel has been considered. The experimental tests have been performed at cutting speed ranging between 350–500 m/min at dry cutting conditions. The machining operations that have been explored included facing, turning, grooving and boring and the 3D topography of the machined surface presented. The results show that good surface finish similar to grinding and dimensional accuracy can be achieved with PcBN tools. |
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Article |
| author |
Sobiyi, K. Sigalas, I. |
| author_facet |
Sobiyi, K. Sigalas, I. |
| author_sort |
Sobiyi, K. |
| title |
High-speed machining of martensitic stainless steel using PcBN |
| title_short |
High-speed machining of martensitic stainless steel using PcBN |
| title_full |
High-speed machining of martensitic stainless steel using PcBN |
| title_fullStr |
High-speed machining of martensitic stainless steel using PcBN |
| title_full_unstemmed |
High-speed machining of martensitic stainless steel using PcBN |
| title_sort |
high-speed machining of martensitic stainless steel using pcbn |
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Інститут надтвердих матеріалів ім. В.М. Бакуля НАН України |
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2016 |
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Получение, структура, свойства |
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| citation_txt |
High-speed machining of martensitic stainless steel using PcBN / K. Sobiyi, I. Sigalas // Сверхтвердые материалы. — 2016. — № 1. — С. 45-51. — Бібліогр.: 16 назв. — англ. |
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ISSN 0203-3119. Сверхтвердые материалы, 2016, № 1 45
UDC 621.9.01
K. Sobiyi*, I. Sigalas
School of Chemical and Metallurgical Engineering University
of the Witwatersrand
*kk_sob@yahoo.com
High-speed machining of martensitic stainless
steel using PcBN
The performance of PcBN cutting tool during its application in the
mass production of components made from AISI 440B stainless steel has been consid-
ered. The experimental tests have been performed at cutting speed ranging between
350–500 m/min at dry cutting conditions. The machining operations that have been
explored included facing, turning, grooving and boring and the 3D topography of the
machined surface presented. The results show that good surface finish similar to grind-
ing and dimensional accuracy can be achieved with PcBN tools.
Keywords: stainless steel, PcBN, surface finish, machining.
INTRODUCTION
In the manufacturing industry, components with high surface fin-
ish and dimensional precision are often required. In ensuring reliability and func-
tionality during the lifetime of these parts, the surfaces are generally hardened.
The hard turning process has been employed in the manufacturing industry as
an alternative to grinding for producing parts from hardened steel, where manufac-
turing cost can be reduced up to 30 % [1]. This process can help to obtain good
surface finish and dimensional and form tolerance [2].
Traditionally, carbide tools are mostly favoured in the machine shop owing to
the low cost of inserts in comparison to some other tools [3, 4]. But these tools are
limited when it comes to abrasive wear resistance, high tolerance and surface fin-
ish, thus, the work material is further subjected to finish grinding [5].
PcBN and ceramics are now becoming popular for mass production manu-
facturing of hardened materials due to their high hardness, wear resistance and
good thermal shock resistance [3, 6–8].
In mass production of simple and complex components, the following factors
were identified as essential for good productivity and success in metal cutting:
workpiece set-up, proper selection of cutting tools, effective coolants, machining
condition optimizations (cutting speeds, feed, and depth of cut), and tool changing
sequences [9].
Many studies have been carried out to explore different facets of hard turning of
hardened steels using the PcBN cutting tool in relationship to the tool wear, surface
finish, and dimensional accuracy [6, 7, 10–14].
Due to the promising results of the low content cBN cutting tool, this study ex-
amines the application of PcBN for the mass production of complex parts. For the
purpose of industrial practice and comparison of the machining method, PcBN
cutting tool performance was investigated as a finishing step during turning of
hardened martensitic stainless steel.
© K. SOBIYI, I. SIGALAS, 2016
www.ism.kiev.ua/stm 46
EXPERIMENTAL
Hard turning tests were performed on hardened martensitic AISI 440 B
stainless steel with chemical composition as given in Table 1. The forged shape
before machining and after machining is given in Fig. 1. The work material was
forged close to the final dimensions, thus only a small volume of material needed
to be removed by the turning process. The material was heat treated by quenching
and tempering to achieve an average hardness between 42 and 44 HRC. Machining
trials were performed using a Hitachi Seiki Hitec Turn 23R III CNC lathe. Three
different turning operations were selected for the machining of the part, the outer
diameter (OD) turning, boring and grooving. To ensure good rigidity of the work-
piece during machining, a clamping system was specially prepared by machining it
to the shape of the workpiece, with small clearance to allow the workpiece to be
easily inserted and removed.
a
b
Fig. 1. Component before (a) and after (b) machining.
Table 1. Chemical composition of the AISI 440 B stainless steel
Composition, wt %
C Cr Mo V Si Mn Fe
0.9 17.5 1.10 0.10 0.45 0.40 Balance
Inserts with three different shapes were used for the turning test. The inserts
tool geometry and tool holders for roughing and finishing operations are given in
Table 2. Rough turning was performed on the workpiece in the presence of coolant
using an uncoated tungsten carbide cutting tool (IC 9250). The finishing was per-
formed in dry cutting conditions using SECO cBN-10 cutting tool (tipped inserts)
containing 50 % cBN. Three machining operations were performed; outer diameter
(OD) turning, facing boring, and grooving. All the inserts and tool holders were
mounted in the turret before the commencement of the machining process so that it
could be completed in a single cycle.
Table 2. Insert geometry and tool holder with designated ISO code
Operations Insert geometry Tool holder
Boring WNGA 080408S A25R PWLNR08
Facing and OD turning WNGA 080408S PWLNR 2020 KO8
Grooving (External) LCMF 160304-0300E-LF CFIR 2020 K03
Grooving (Internal) LCGN 130304.0300S-LF A20R-CGFR 1303
ISSN 0203-3119. Сверхтвердые материалы, 2016, № 1 47
The machining process was performed at high speed, with the assumption that
the parts would be mass produced. The machining conditions for roughing and
finishing are given in Table 3. The depth of cut was kept constant at 0.3 mm. The
sequence of the machining was facing, followed by OD turning, then boring and
lastly grooving. The machining operations were repeated for the production of ten
identical parts.
Table 3. Machining conditions
Roughing Finishing
Facing
OD
turning
Boring Grooving Facing
OD
turning
Boring Grooving
Speed,
m/min
150 150 200 300 350 350 500 400
Feed,
mm/rev
0.35 0.35 0.15 0.1 0.1 0.1 0.1 0.1
After the end of the turning test, part surface finish was measured in the 2D and
3D arrangements with two diamond stylus contact profilometers. In addition, the
three-dimensional topographic maps of the machined surfaces were produced using
scanning technique. A set of the 2D roughness parameters was determined by sim-
ple roughness measurements using a shop floor T8000 (Hommel Tester) instrument
using probe TKU 300. Moreover, 3D measurements were carried out on the
scanned area of 10×0.5 mm (OD) and 1.5×0.5 mm (groove) by means of the pro-
filometer. The optical 3D image of the OD was taken using an Olympus LEXT
OLS410 3D laser measuring microscope.
RESULTS AND DISCUSSION
The surface roughness of the machined parts was measured in areas as indicated
in Fig. 2 with an average of five different points recorded. The average surface
finish Ra of the outer diameter was 0.545 µm and of the groove of the part
0.37 µm. The lower Ra recorded is due to the tool feed direction used in the ma-
chining process during boring; this resulted to about 32 % reduction of the surface
roughness. This surface roughness corresponds to the N6 and N5; ISO 1302:1992
code [ISO CODE], which is applicable for bearing surfaces produced by grinding.
Fig. 2. Points on machined components indicating areas where the surface roughnesses were
measured: 1 – OD; 2 – groove.
www.ism.kiev.ua/stm 48
An example of the 2D profiles and 3D topographies of the surfaces OD and
groove are presented in Figs. 3 and 4, respectively. The measured 2D parameters
are given in Table 4. The ratio of Rt to Rz for the OD and groove of the machined
components were about 1.466 and 1.083, respectively. The surface roughness peak
height parameter Rp, showed a correlation with the maximum contact deforma-
tions, which are normally obtained during machining of rough surfaces. Thus, the
ratio Rp/Rt and Rv/Rt relates the surface profile resistance to abrasive wear and
deformation between the contacting surfaces [15].
0 1 2 3 4 5 6 7 8 9 mm
–4
–2
0
2
4
μm
a
0
7
8
0
9
10
mm
4
5
6
1
2
3
10
20
30
40
50
0.5 0.25 mm
b
c
Fig. 3. 2D profiles, length = 9.87 mm, Rt = 7.18 μm, scale = 10.0 μm (a) and 3D topographies
(b) of OD surface: 1 – 3D optical image (c).
This result shows that a good surface finish can be produced using the cBN cutting
tool under industrial machining conditions. The hard turning operations with cBN can
be used for substituting traditional machining operations that involve a grinding proc-
ISSN 0203-3119. Сверхтвердые материалы, 2016, № 1 49
ess after the turning operation, in support of Grzesik [8]. Consequently, the roughness
falls within the high precision hard turning limits as indicated by Bryne et al. [6].
0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 mm
–4
–2
0
2
4
μm
a
0
0
mm
4 1
2
0.2
150 μm
0.4
0.6
0.8
1.0
1.2
1.4
b
Fig. 4. 2D profiles, length = 1.49 mm, Rt = 3.69 μm, scale = 10.0 μm (a) and 3D topographies
(b) of the groove.
Table 4. 2D Parameters of the OD and groove surfaces
Parameters OD surface, µm Groove surface, µm
Rt 3.49 2.73
Rz 2.38 2.52
Rp 0.838 1.54
Rv 1.55 0.975
Ra 0.545 0.370
Rq 0.644 0.472
The dimensional and geometrical accuracy of some selected areas of the ma-
chined component were measured after machining ten identical parts, to observe
deviation of the actual machined values from the dimensional requirements stipu-
lated in the component design. The dimensional deviation of the measured selected
parts of the component in relationship to the length, diameter and concentricity are
given in Table 5. The concentricity shows the maximum deviation of about 1 µm
from the required deviation, the deviation in the straightness or length was between
www.ism.kiev.ua/stm 50
14 and 18 µm, and the geometric deviation was between 0.135 and 0.21 µm. The
results obtained were similar to the findings by Abrao et al. [14], confirming an
achievable and acceptable tolerance range of IT5 within the machine tool shop
during mass production of similar components.
Table 5. Dimensional deviation from specified
Characteristics Size, mm Error, mm
Length 31.75±0.1 0.018
Diameter 52±0.05 0.014
Length 11±0.05 0.0135
Concentricity 0.005 A” 0.001
Diameter 45.1±0.03 0.016
Diameter 41.6±0.05 0.0206
The tight tolerance is a result of the high stiffness and accuracy of the CNC ma-
chine coupled with the excellent properties of the cBN cutting tool, such as high
abrasion and thermal shock resistance [6, 16].
CONCLUSION
The overall surface finish and dimensional accuracy generated during the appli-
cation of PcBN tool for machining the specified shape shows a component accept-
able tolerance range (IT5) with good surface finish (between N5 and N6) similar to
that achieved with grinding operation.
The authors thank the CME precisions (Pty) Ltd. for the use of their facilities to carry
out the work. We thank Patrick Johnson for his assistance during the machining trials.
This work was funded by CoE-SM and Castco precisions (Pty) Ltd.
Розглянуто робочі характеристики ріжучого інструменту, оснащеного
полікристалічним кубічним нітридом бору (КНБ), що використовують в масовому вироб-
ництві виробів з нержавіючої сталі AISI 440B. Експериментальні випробування проводили
при швидкості різання в діапазоні від 350 до 500 м/хв в умовах сухого різання. Представ-
лено операції обробки, що включають обточування торця, точіння, прорізання канавок і
свердління, а також 3D-топографія обробленої поверхні. Результати показують, що,
застосовуючи в інструментах полікристалічний КНБ, можна досягти хорошої якості
обробки поверхні і точності розмірів, таких же як при шліфуванні.
Ключові слова: нержавіюча сталь, PcBN, чистова обробка поверхні,
обробка.
Рассмотрены рабочие характеристики режущего инструмента, осна-
щенного поликристаллическим кубическим нитридом бора (КНБ), используемого в массо-
вом производстве изделий из нержавеющей стали AISI 440B. Экспериментальные испы-
тания проводили при скорости резания в диапазоне от 350 до 500 м/мин в условиях сухого
резания. Представлены операции обработки, включающие обточку торца, точение, про-
резание канавок и сверление, а также 3D-топография обработанной поверхности. Ре-
зультаты показывают, что, применяя в инструментах поликристаллический КНБ, мож-
но достичь хорошего качества обработки поверхности и точности размеров, таких же
как при шлифовании.
Ключевые слова: нержавеющая сталь, PcBN, чистовая обработка по-
верхности, обработка.
ISSN 0203-3119. Сверхтвердые материалы, 2016, № 1 51
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Received 27.03.15
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>>
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/NLD (Gebruik deze instellingen om Adobe PDF-documenten te maken voor kwaliteitsafdrukken op desktopprinters en proofers. De gemaakte PDF-documenten kunnen worden geopend met Acrobat en Adobe Reader 5.0 en hoger.)
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/ENU (Use these settings to create Adobe PDF documents for quality printing on desktop printers and proofers. Created PDF documents can be opened with Acrobat and Adobe Reader 5.0 and later.)
/RUS ()
>>
/Namespace [
(Adobe)
(Common)
(1.0)
]
/OtherNamespaces [
<<
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(4.0)
]
/OmitPlacedBitmaps false
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/OmitPlacedPDF false
/SimulateOverprint /Legacy
>>
<<
/AddBleedMarks false
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/PresetSelector /MediumResolution
>>
/FormElements false
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>>
]
>> setdistillerparams
<<
/HWResolution [2400 2400]
/PageSize [612.000 792.000]
>> setpagedevice
|