Effect of Grinding Parameters on the Surface Quality of Cutting Tools Made of High-Speed Low-Alloy Steels
The occurrence of defects caused by sharpening leads to the considerable variation of lifetime of cutting tools under identical process conditions. The loss of cutting ability of cutting tools or the change of the blade original geometry influences the quality of the surface finish as well as both d...
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irk-123456789-1735122020-12-08T01:27:01Z Effect of Grinding Parameters on the Surface Quality of Cutting Tools Made of High-Speed Low-Alloy Steels Jaworski, J. Trzepiecinski, T. Stachowicz, F. Научно-технический раздел The occurrence of defects caused by sharpening leads to the considerable variation of lifetime of cutting tools under identical process conditions. The loss of cutting ability of cutting tools or the change of the blade original geometry influences the quality of the surface finish as well as both dimensional and shape accuracy of workpieces. The effect of the grinding parameters on the surface finish of selected high-speed steels has been investigated. The influence of the grinding parameters has been defined especially for surface roughness, grinding forces and grinding ratio with a wide range of grinding parameters. It is found that the value of average roughness (Ra ) parameter decreases together with an increase in the grinding depth and the feed length. Furthermore, the value of Ra increases proportionally to the grinding depth. To increase the efficiency of sharpening, it is required to increase the feed length other than the grinding depth. 2016 Article Effect of Grinding Parameters on the Surface Quality of Cutting Tools Made of High-Speed Low-Alloy Steels / J. Jaworski, T. Trzepiecinski, F. Stachowicz // Проблемы прочности. — 2016. — № 4. — С. 110-118. — Бібліогр.: 31 назв. — англ. 0556-171X http://dspace.nbuv.gov.ua/handle/123456789/173512 539.4 en Проблемы прочности Інститут проблем міцності ім. Г.С. Писаренко НАН України |
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Научно-технический раздел Научно-технический раздел Jaworski, J. Trzepiecinski, T. Stachowicz, F. Effect of Grinding Parameters on the Surface Quality of Cutting Tools Made of High-Speed Low-Alloy Steels Проблемы прочности |
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The occurrence of defects caused by sharpening leads to the considerable variation of lifetime of cutting tools under identical process conditions. The loss of cutting ability of cutting tools or the change of the blade original geometry influences the quality of the surface finish as well as both dimensional and shape accuracy of workpieces. The effect of the grinding parameters on the surface finish of selected high-speed steels has been investigated. The influence of the grinding parameters has been defined especially for surface roughness, grinding forces and grinding ratio with a wide range of grinding parameters. It is found that the value of average roughness (Ra ) parameter decreases together with an increase in the grinding depth and the feed length. Furthermore, the value of Ra increases proportionally to the grinding depth. To increase the efficiency of sharpening, it is required to increase the feed length other than the grinding depth. |
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Article |
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Jaworski, J. Trzepiecinski, T. Stachowicz, F. |
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Jaworski, J. Trzepiecinski, T. Stachowicz, F. |
| author_sort |
Jaworski, J. |
| title |
Effect of Grinding Parameters on the Surface Quality of Cutting Tools Made of High-Speed Low-Alloy Steels |
| title_short |
Effect of Grinding Parameters on the Surface Quality of Cutting Tools Made of High-Speed Low-Alloy Steels |
| title_full |
Effect of Grinding Parameters on the Surface Quality of Cutting Tools Made of High-Speed Low-Alloy Steels |
| title_fullStr |
Effect of Grinding Parameters on the Surface Quality of Cutting Tools Made of High-Speed Low-Alloy Steels |
| title_full_unstemmed |
Effect of Grinding Parameters on the Surface Quality of Cutting Tools Made of High-Speed Low-Alloy Steels |
| title_sort |
effect of grinding parameters on the surface quality of cutting tools made of high-speed low-alloy steels |
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Інститут проблем міцності ім. Г.С. Писаренко НАН України |
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2016 |
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Научно-технический раздел |
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http://dspace.nbuv.gov.ua/handle/123456789/173512 |
| citation_txt |
Effect of Grinding Parameters on the Surface Quality of Cutting Tools Made of High-Speed Low-Alloy Steels / J. Jaworski, T. Trzepiecinski, F. Stachowicz // Проблемы прочности. — 2016. — № 4. — С. 110-118. — Бібліогр.: 31 назв. — англ. |
| series |
Проблемы прочности |
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| first_indexed |
2025-07-15T10:15:38Z |
| last_indexed |
2025-07-15T10:15:38Z |
| _version_ |
1837707601863770112 |
| fulltext |
UDC 539.4
Effect of Grinding Parameters on the Surface Quality of Cutting Tools Made
of High-Speed Low-Alloy Steels
J. Jaworski, T. Trzepiecinski,
1
and F. Stachowicz
Faculty of Mechanical Engineering and Aeronautics, Rzeszów University of Technology, Rzeszów,
Poland
1 tomtrz@prz.edu.pl
The occurrence of defects caused by sharpening leads to the considerable variation of lifetime of
cutting tools under identical process conditions. The loss of cutting ability of cutting tools or the
change of the blade original geometry influences the quality of the surface finish as well as both
dimensional and shape accuracy of workpieces. The effect of the grinding parameters on the surface
finish of selected high-speed steels has been investigated. The influence of the grinding parameters
has been defined especially for surface roughness, grinding forces and grinding ratio with a wide
range of grinding parameters. It is found that the value of average roughness (Ra ) parameter
decreases together with an increase in the grinding depth and the feed length. Furthermore, the value
of Ra increases proportionally to the grinding depth. To increase the efficiency of sharpening, it is
required to increase the feed length other than the grinding depth.
Keywords: grinding, high-speed steel, surface roughness, temperature.
Introduction. Grinding is an abrasive finishing process. In the process of grinding,
grains separate and form new cutting edges. Therefore, grinding is a self-sharpening
process. The surface roughness is one of the most critical quality constraints for the
selection of grinding factors in process planning. The surface roughness prediction in the
process of grinding is the main task determining the quality of the cutting tool [1]. The
other parameters of interest are the wear ratio and the volume ratio of the removed material.
The quality of the surface layer is usually evaluated according to the following factors: the
depth of subsurface layers with structure and/or microhardness modifications, and the
surface roughness [2, 3].
The wear resistance of the tool material has an influence on the tool lifetime [4–7]. A
certain number of important properties of tool materials such as hardness, strength,
temperability and thermal conductivity is required to ensure the long lifetime of cutting
tools. High-speed low-alloy steels belong to the subgroup of high-speed steels (HSS) with
the composition of %W�1.5%Mo�12%. To ensure that the quality requirements are
satisfied during the production of tools made of high-speed steels, it is very important to
provide their high cutting ability [8–11]. The tool wear is one of the most important
characteristics defining the accuracy of technological system of parts machining [12, 13].
The data on lifetime of the tool made of high-speed low-alloyed steels presented in the
paper are inconsistent. Determination of the machining properties and definition of the tool
operational reliability as one of the elements of this system are realized using the experimental
data with consideration of the blade edge wear depending on the machining time or path.
However, solving the problems on the reliability of the technological system for machining
parts, in particular the tool reliability (optimal planning of the tool repair or replacement),
requires the knowledge of not only the expected wear value for each period of its service
life, but also its distribution in accordance with the assumed tool lifetime under cutting, or
distribution of the tool life and the assumed value of wear of the tool flank (VB) [12–14].
The empirical dependence between the tool life T and the machining parameters in the
form of T CT v kc� (where CT is the constant equal to T for vc � 1m/min and k is the
© J. JAWORSKI, T. TRZEPIECINSKI, F. STACHOWICZ, 2016
110 ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2016, ¹ 4
negative slope of the T vc� curve) is still used for engineering calculations. It is obvious
that the calculated tool lifetime is generally different from the tool life obtained from the
investigation. In case the statistical parameters of the wear function of the tool flank VB are
determined in the investigation of the tool lifetime under cutting, it can be established that
the expected value of the parameter VB might be described by normal distribution during
its standard service period [15–18].
The paper considers effect of grinding parameters on the surface finish of selected
high-speed low-alloy steels. The influence of the grinding parameters has been determined
particularly for surface roughness, grinding forces and grinding ratio with a wide range of
grinding parameters.
1. Description. It is a well-known fact that the implementation of the wear function
VB f t� ( ) for high-speed low-alloy steel tools involves three wear-out periods: lapping,
normal use and critical wear. Based on the statistical parameters of random functions of
VB f t� ( ), where t is the time evaluated using the experimental data, it can be determined
that under normal wear conditions the function of the expected wear mVB is linear. In
accordance with this approach the dependence of wear on the time function is more reliable
since it is obtained not from the single investigation, but using the expected value of the
function of VB f t� ( ).
Figure 1 presents the effect of the machining time on the wear value VB. The process
of machining of steel 100Cr6 is carried out using the turning tool made of HS18-0-1 steel.
The cutting parameters are as follows: vc � 10 m/s, f � 0.3 mm/rev, and a p � 2 mm.
The experiments are performed under laboratory conditions, where heat treatment and
sharpening parameters are constant. A certain number of random wear functions of
VB f t� ( ) (Fig. 1) is determined from each investigation on the test specimens. In the
period of lapping, the conditions for flank wear are different from those compared to the
normal wear. The temperature determined from the experiments during lapping is slightly
different from the temperature at the beginning of normal wear [19]. The pressure on the
tool flank while cutting using the tool after sharpening attains high values, since the force
on the tool flank surface covers the small area of the contact between the tool flank and the
workpiece [20, 21]. Consequently, pressure acting on the tool flank surface is the dominant
factor in determining the wear rate during lapping. This pressure is practically independent
of the cutting speed. The stabilization of unit pressure on the tool flank is observed at the
end of lapping. An increase in the forces acting on the tool flank surface is directly
Fig. 1. Effect of the machining time on the wear value VB.
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Effect of Grinding Parameters on the Surface Quality ...
proportional to the size of wear VB. The amount of wear VB is identical for the specific
cutting conditions and grades of the high-speed steel with similar chemical composition
(Fig. 1).
The results of investigations concerning the possibility of using high-speed low-alloy
steel for punches for sheet blanking are presented in Fig. 2. The analyzed electric motor
parts are made of 0.5 mm thick generator steel sheet type EP 470-50A coated with the
insulating varnish. The blanking process is performed using high-speed press equipped
with the specially constructed precision slide guide. The blanking efficiency is of 400 parts
per minute.
The presented case of implementation of the random wear function of VB f t� ( ) is
different from that one shown in Fig. 1 and indicates the effect of the dominant factors that
have an influence on the process of wear. These factors include both the elements
controlling the operation conditions and the parameters of the tool initial state.
The experiments are performed using the tools controlling the conditions of heat
treatment and sharpening parameters. However, as shown in Fig. 1 the implementation of
the wear function of VB f t� ( ) demonstrates its fanlike distribution. From the beginning
of the tool operation different rates of the tool wear are observed. The dominant factor that
significantly effects the wear dispersion and the tool lifetime is the defects due to tool
sharpening. They cause the change in the nature of wear distribution. Such hazardous
defects should be eliminated, and a more detailed analysis of the origins of this effect is
required.
The increase in the wear rate of the tool blade with an increase of the sharpening
depth shown in Fig. 3 can be explained by the greater depth of the damaged surface layer of
high-speed steel containing a larger amount of austenite. Such variation of the wear
function causes damage to the tool in the cutting process before sharpening. Tempering of
high-speed steel tools under the wear surface conditions can also be referred to such
defects. The higher the temperature on the contact surface during sharpening, the greater
the depth of low-hardness layer location.
The different cutting depths at which sharpening of tools is realized cause a fanlike
distribution of the wear curves. The occurrence of sharpening defects increases the wear
dispersion of the cutting tool blade compared to that observed in Fig. 1. The loss of the
cutting ability of abrasive tools or the change in their original shape influences the quality
of the surface finish and dimensional accuracy of sharpened tools. For this reason, the
abrasive tool wear is the primary criterion of evaluation of the grindability of the
Fig. 2. Wear of the tool flank of the punches made of HS2-5-1.
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J. Jaworski, T. Trzepiecinski, and F. Stachowicz
workpiece, which consequently has a decisive influence on the lifetime of grinding tools
[22, 23]. Grindability means the property of a material to be ground in compliance with
specifications or criteria posed by the processing conditions [24].
It is a well-known fact that during sharpening of tools their residual lifetime can be
varied [19]. The tool lifetime reduction due to cutting is caused by slippages on the surface
of the tool point, which are formed during tool sharpening. High grinding temperatures
facilitate the formation of the increased amount of secondary austenite in the surface layer
of the high-speed steel [25, 26], which reduces the tool lifetime under cutting. Therefore,
the possibility of the occurrence of these defects should be eliminated by the choice of
adequate sharpening parameters.
2. Materials and Method. The specimens with dimensions of 6 6 65� � mm were
made of high-speed low-alloy steels. Table 1 shows their chemical composition. The heat
treatment was conducted according to the recommendations from the standards.
The investigations are carried out on the flat-surface grinder with a 95A24K disk-type
grinding wheel without cooling. The influence of the grinding parameters is determined
particularly for the surface roughness and the coefficient of grinding with a large range of
grinding parameters: vc � 20 m/s, a p � 0.005–0.035 mm, and v f � 2–6 m/min without
cross-feed along the entire width of the specimen. After each investigation the disk-type
grinding wheel is honed by diamond honing. The forces are measured using the dynamometer,
whereas the surface roughness is measured using the profilograph Surtronic 3+.
Fig. 3. Effect of the grinding depth ap on the durability of the cutting edge of pull broaches.
T a b l e 1
High-Speed Low-Alloy Steel Grades: Chemical Composition and Hardness
Steel
grade
Hardness
(HRC)
Chemical composition (wt.%)
C W Mo Cr V Si
HS3-3-3 64 1.00 2.98 2.83 4.27 2.30 –
HS2-5-2 64 0.99 1.67 4.79 3.78 1.15 –
HS3-1-1 63–68 1.11 3.35 1.15 4.65 1.75 2.05
HS6-5-2 64 0.82 5.55 5.13 4.27 2.06 –
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Effect of Grinding Parameters on the Surface Quality ...
3. Results and Discussion. The results of investigations of the cutting forces
depending on the longitudinal feed are shown in Fig. 4. The value of the cutting force
increases with the increase in the values of longitudinal feed and cutting depth. The
smallest value of cutting forces was registered in the process of grinding of HS2-5-2 and
HS6-5-2 steels. In contrast, the largest grinding forces were found for HS3-3-3 and
HS3-1-1 steels. The fact that the cutting forces in grinding of HS3-1-1 steel are higher than
those of HS3-3-3 steel with a lower content of vanadium, can be attributed to a higher
content of carbon in HS3-3-3 steel [19]. From the point of view of the surface layer quality,
the improved efficiency of sharpening requires the increase of the feed length other than the
grinding depth. The ultimate stresses in the surface layer were not investigated. It is known
that their source is the temperature gradient on the machined surface layer. It can be
assumed that for HS3-1-1 steel the level of stresses is a little higher than for HS6-5-2 steel.
The development of high temperature during grinding leads to changes in the metallurgical
structure and development of high internal stresses to the level where cracks can be formed
[20]. As a result of the investigation it was determined that the level of ultimate stresses did
not cause the formation of grinding cracks.
The experimental results confirm the higher tendency to structural modifications of
HS3-1-1 steel during grinding. The surface roughness is a very important parameter for the
machined surface quality. The results of the measurement of the value of Ra are presented
in Figs. 5 and 6. No substantial differences in the surface finish of the selected steel grades
were observed: it decreases with the grinding depth and feed length, in each case. The
investigated the differences in the surface finish have no effect on the machinability of
tools. Kiyak [27] has found that an increase of the workpiece speed produces a lower
surface roughness in dry grinding. It was also found that a higher feed rate increases the
surface roughness. Matsou [28] has reported that an increase in the material removal rate
produces a higher surface roughness. Furthermore, the results indicate that the width of the
wheel do not affect the surface quality. One of the main factors influencing the surface
roughness is the wheel type.
Fig. 4. Effect of the feed length on the value of grinding forces (Py is the inverted grinding force and
Pz is the circumferential force).
114 ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2016, ¹ 4
J. Jaworski, T. Trzepiecinski, and F. Stachowicz
Figure 7 shows the examples of two roughness profiles. Figure 7a presents the
roughness profile of HS6-5-2 (a p � 0.005 mm and v f � 2 m/min). In this case, the
smallest value of Ra was observed considering all the tested specimens. Figure 7b
presents the roughness profile of steel HS2-5-2. In that case, the value of Ra was 0.63 �m
(a p � 0.015 mm and v f � 4 m/min).
The investigations of the influence of the grinding depth in the process of sharpening
of pull broaches on their wear demonstrate a fanlike distribution of tooth wear. Furthermore,
an increase in the wear rate with the grinding depth is observed. An increase in damage
during sharpening of the surface layer of high-speed steel can be explained by a large
amount of secondary austenite.
The investigations on the type of wear of the grinding wheels [29, 30] suggest that
their wear is primarily dependent on the properties of the workpiece, abrasive, cutting
forces, temperature, length of the contact zone, and contact time. An increase in the
grinding wheel width at the constant crossfeed does not produce any noticeable changes of
the abrasive grain wear intensity. Authors [31] has concluded that an increase in the
grinding wheel hardness, which does not considerably influence the abrasive grains wear,
causes a significant reduction of the grinding wheel wear due to bond spalling.
Fig. 5. Effect of the cutting depth on the average roughness value.
Fig. 6. Effect of the grade of high-speed low-alloy steel on the average roughness value.
ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2016, ¹ 4 115
Effect of Grinding Parameters on the Surface Quality ...
Conclusions. Depending on the cutting conditions, the period of normal wear of the
blade manifests different wear values VB and various periods of lapping. Depending on the
adopted wear criterion and the cutting process conditions, the lapping time taken to attain
the end of the tool lifetime could be quite significant. The dominant factor controlling the
wear rate in the period of lapping was found to be the pressure on the tool flank surface,
which is practically independent of the cutting speed. At the end of the period of lapping,
the stabilization of the unit pressure on the tool flank was observed. The increase in the
forces acting on the tool flank was directly proportional to the value of wear VB. The
fanlike function of wear distribution is often the result of the effect of defects from tool
sharpening, which can lead to the increased wear dispersion of the tool under cutting.
The results of investigations of the grinding properties of HS2-5-2 steel show that the
proper selection of the chemical composition makes it possible to improve the grinding
properties of high-speed low-alloy steels. The temperature rise during sharpening is the one
of the main phenomena affecting the tool surface layer quality. Therefore, application of
borazon abrasive disks or suitable grinding fluid can effectively reduce the temperature
during tool sharpening.
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grinding,” CIRP Ann.-Manuf. Techn., 48, No. 2, 581–598 (1999).
31. J. Borkowski and P. Borkowski, “The influence of elementary effects on grinding
wheel wear,” Arch. Civ. Mech. Eng., 2, No. 1-2, 21–34 (2002).
Received 10. 08. 2016
118 ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2016, ¹ 4
J. Jaworski, T. Trzepiecinski, and F. Stachowicz
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/ENU (Use these settings to create Adobe PDF documents best suited for high-quality prepress printing. Created PDF documents can be opened with Acrobat and Adobe Reader 5.0 and later.)
>>
/Namespace [
(Adobe)
(Common)
(1.0)
]
/OtherNamespaces [
<<
/AsReaderSpreads false
/CropImagesToFrames true
/ErrorControl /WarnAndContinue
/FlattenerIgnoreSpreadOverrides false
/IncludeGuidesGrids false
/IncludeNonPrinting false
/IncludeSlug false
/Namespace [
(Adobe)
(InDesign)
(4.0)
]
/OmitPlacedBitmaps false
/OmitPlacedEPS false
/OmitPlacedPDF false
/SimulateOverprint /Legacy
>>
<<
/AddBleedMarks false
/AddColorBars false
/AddCropMarks false
/AddPageInfo false
/AddRegMarks false
/ConvertColors /ConvertToCMYK
/DestinationProfileName ()
/DestinationProfileSelector /DocumentCMYK
/Downsample16BitImages true
/FlattenerPreset <<
/PresetSelector /MediumResolution
>>
/FormElements false
/GenerateStructure false
/IncludeBookmarks false
/IncludeHyperlinks false
/IncludeInteractive false
/IncludeLayers false
/IncludeProfiles false
/MultimediaHandling /UseObjectSettings
/Namespace [
(Adobe)
(CreativeSuite)
(2.0)
]
/PDFXOutputIntentProfileSelector /DocumentCMYK
/PreserveEditing true
/UntaggedCMYKHandling /LeaveUntagged
/UntaggedRGBHandling /UseDocumentProfile
/UseDocumentBleed false
>>
]
>> setdistillerparams
<<
/HWResolution [2400 2400]
/PageSize [612.000 792.000]
>> setpagedevice
|