Analysis of hard turning process: thermal aspects

doi:10.1007/s40436-015-0124-3

Abstract

Abstract: In manufacturing sector, hard turning has emerged as a vital machining process for cutting hardened steels. Besides many advantages of hard turning operations, one has to implement to achieve close tolerances in terms of surface finish, high product quality, reduced machining time, low operating cost and environmental friendly characteristics. In the study, three dimensional (3D) computer aided engineering (CAE) based simulation of hard turning by using commercial software DEFORM 3D has been compared to the experimental results of stresses, temperatures and tool forces in machining of AISI D3 and AISI H13 steel using mixed ceramic inserts (CC6050). In the following analysis, orthogonal cutting models are proposed, considering several processing parameters such as cutting speed, feed and depth of cut. An exhaustive friction modelling at the tool-work interface is carried out. Work material flow around the cutting edge is carefully modelled with adaptive re-meshing simulation capability of DEFORM 3D. The process simulations are performed at constant feed rate (0.075 mm/r) and cutting speed (155 m/min), and analysis is focused on stresses, forces and temperatures generated during the process of machining. Close agreement is observed between the CAE simulation and experimental values.

Key words: Hard turning, Computer aided engineering (CAE), Computational machining, Finite element method

Varaprasad Bhemuni, Srinivasa Rao Chalamalasetti, Pavan Kumar Konchada, Venkata Vinay Pragada. Analysis of hard turning process: thermal aspects[J]. Advances in Manufacturing, 2015, 3(4): 323-330.

TrendMD

References

1. Byrne G, Dornfeld D, Denkena B (2003) Advanced cutting technology. Ann CIRP 52(2):483-507

2. Klocke F, Brinksmeier E, Weinert K (2005) Capability profile of hard cutting and grinding processes. Ann CIRP 54(2):557-580

3. Klocke F, Kratz H (2005) Advanced tool edge geometry for high precision hard turning. Ann CIRP 54(1):47-50

4. Denkena B, Becker JC, de Leon-Garcia L (2005) Study of the influence of the cutting edge micro geometry on the cutting forces and wear behavior in turning operations. In: Proceedings of the 8th CIRP, international workshop on modelling of machining operations, Chemnitz, pp 503-507

5. Özel T, Hsu TK, Zeren E (2005) Effects of cutting edge geometry, workpiece hardness, feed rate and cutting speed on surface roughness and forces in finish turning of hardened AISI H13 steel. Int J Adv Manuf Technol 25:262-269

6. Zou B, Chen M, Li S (2011) Study on finish-turning of NiCr20TiAl nickel-based alloy using Al₂O₃/TiN-coated carbide tools. Int J Adv Manuf Technol 53:81-92

7. Fahad M, Mativenga PT, Sheikh MA (2012) A comparative study of multilayer and functionally graded coated tools in high-speed machining. Int J Adv Manuf Technol 62:43-57

8. Gopalsamy BM, Mondal B, Ghosh S (2009) Optimisation of machining parameters for hard machining: grey relational theory approach and ANOVA. Int J Adv Manuf Technol 45:1068-1086

9. Ahilan C, Kumanan S, Sivakumaran N (2010) Application of grey based taguchi method in multi response optimization of turning process. Adv Prod Eng Manag 5(3):171-180

10. Tzeng CJ, Lin YH, Yang YK et al (2009) Optimization of turning operations with multiple performance characteristics using the taguchi method and grey relational analysis. J Mater Process Technol 209:2753-2759

11. Kazancoglu Y, Esme U, Bayramoglu M et al (2011) Multi-objective optimization of the cutting forces in turning operations using the grey-based taguchi method. Mater Technol 45(2):105-110

12. Senthilkumar N, Tamizharasan T, Anandakrishnan V (2013) An ANN approach for predicting the cutting inserts performances of different geometries in hard turning. Adv Prod Eng Manag 8(4):231-241

13. Özel T (2003) Modeling of hard part machining: effect of insert edge preparation for CBN cutting tools. J Mater Process Technol 141:284-293

14. Yen YC, Jain A, Altan T (2004) A finite element analysis of orthogonal machining using different tool edge geometry. J Mater Process Technol 146:72-81

15. Hua J, Shivpuri R, Cheng X et al (2005) Effect of feed rate, workpiece hardness and cutting edge on subsurface residual stress in hard turning of bearing steel using chamfer and hone edge geometry. Mater Sci Eng, A 394:238-248

16. Chen L, ElWardany TI, Nasr M et al (2006) Effects of edge preparation and feed when hard turning a hotwork die steel with polycrystalline cubic boron nitride tools. Ann CIRP 55(1):88-92

17. Umbrello D, Rizzuti S, Outeiro JC (2008) Hardnessbased flowstress for numerical simulation of hardmachining AISI H13 tool steel. J Mater Process Technol 199(1-3):64-73

18. Karpat Y, Özel T (2008) Mechanics of high speed machining with curvilinear tools. Int J Mach Tools Manuf 49:195-208

19. Ceretti E, Lazzaroni C, Menegardo L et al (2000) Turning simulations using a three-dimensional FEM code. J Mater Process Technol 98:99-103

20. Guo Y, Liu CR (2002) 3D FEA modeling of hard turning. ASME J Manuf Sci Eng 124:189-199

21. Aurich JC, Bil H (2006) 3D finite element modelling of segmented chip formation. Ann CIRP 55(1):47-50

22. Rosochowska M, Balendra R, Chodnikiewicz K (2003) Measurements of thermal conductance. J Mater Process Technol 135:204-210

23. Incropera FP, DeWitt DP (2001) Fundamentals of heat and mass transfer. Willey, New York

24. Johnson GR, Cook WH (1985) Fracture characteristic of three metals subjected to various strains. Eng Fract Mech 21:3

[1]	Ali Kalyon, Mustafa Günay, Dursun Özyürek. Application of grey relational analysis based on Taguchi method for optimizing machining parameters in hard turning of high chrome cast iron [J]. Advances in Manufacturing, 2018, 6(4): 419-429.
[2]	Ramanuj Kumar, Ashok Kumar Sahoo, Purna Chandra Mishra, Rabin Kumar Das. Comparative study on machinability improvement in hard turning using coated and uncoated carbide inserts: part II modeling, multi-response optimization, tool life, and economic aspects [J]. Advances in Manufacturing, 2018, 6(2): 155-175.
[3]	Ramanuj Kumar, Ashok Kumar Sahoo, Purna Chandra Mishra, Rabin Kumar Das. Comparative investigation towards machinability improvement in hard turning using coated and uncoated carbide inserts: part I experimental investigation [J]. Advances in Manufacturing, 2018, 6(1): 52-70.
[4]	G. Buffa, M. De Lisi, E. Sciortino, L. Fratini. Dissimilar titanium/aluminum friction stir welding lap joints by experiments and numerical simulation [J]. Advances in Manufacturing, 2016, 4(4): 287-295.
[5]	A. Ducato, G. Buffa, L. Fratini, R. Shivpuri. Dual phase titanium alloy hot forging process design: experiments and numerical modeling [J]. Advances in Manufacturing, 2015, 3(4): 269-281.
[6]	Nejah Tounsi, Tahany El-Wardany. Finite element analysis of chip formation and residual stresses induced by sequential cutting in side milling with microns to submicron uncut chip thickness and finite cutting edge radius [J]. Advances in Manufacturing, 2015, 3(4): 309-322.