Title: Optimisation of cutting conditions in hard turning using ceramic-coated and uncoated PCBN cutting tools

Authors: Ty G. Dawson, Thomas R. Kurfess

Addresses: Milliken Research Corporation, P.O. Box 1927, M-179, Spartanburg, SC 29303, USA. ' George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, MARC 435, Atlanta, 30332-0405 GA, USA

Abstract: Traditionally, hardened steels have been finished by grinding, but improvements in machine tools and cutting materials allow machining of hardened steels. This research addresses the influence of cutting parameters on tool life and cost. Experimental tests were performed to calibrate the well-known Taylor life model, and validation tests with both uncoated and TiAlN-coated PCBN tools show the predictive capability of the model. The life model is incorporated into a cost optimisation that allows determination of optimal cutting conditions. This analysis shows that the improved wear resistance of TiAlN-coated tools allows higher productivity rates, improved surface finish, and reduced part cost.

Keywords: hard turning; CBN; PCBN cutting tools; tool wear; tool life; optimisation; hardened steels; ceramic-coated tools; uncoated tools; productivity rates; surface finish; part costs.

DOI: 10.1504/IJMTM.2008.017738

International Journal of Manufacturing Technology and Management, 2008 Vol.14 No.3/4, pp.448 - 460

Published online: 28 Mar 2008 *

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