Article: Effect of wear progression in an 'S'-type mixed ceramic tool on machining forces and surface roughness in the turning of hardened AISI 4140 steel Journal: International Journal of Machining and Machinability of Materials (IJMMM) 2019 Vol.21 No.3 pp.228 - 243 Abstract: This study investigates the behaviours of machining forces and the roughness of a workpiece in the dry turning of AISI 4140 steel hardened at 55 HRC due to the wear evolution of a mixed ceramic tool with 'S'-type blade microgeometry. Six end-of-life tests were performed by combining three levels of cutting speed and two feed rate levels. A constant depth of cut was maintained. According to the results, the highest cutting speed and feed rates had a significant effect on the flank and crater wear of the tool and gradually changed the values of the forces and roughness. The feed rate was the parameter with the highest effect on the output parameters of the process. The crater wear evolution caused a reduction of the machining forces. Meanwhile, flank wear formation promoted an increase in the machining force components. From the point of view of the influence of tool wear processes, and, unlike what happens with flank wear, the crater formation affects favourably the surface roughness, as its evolution promoted the reduction of the R<SUB align="right"><SMALL>a</SMALL></SUB> values in all cutting conditions. Inderscience Publishers - linking academia, business and industry through research

Title: Effect of wear progression in an 'S'-type mixed ceramic tool on machining forces and surface roughness in the turning of hardened AISI 4140 steel

Authors: Jéferson Hilário W. Nicolodi; Luiz Airton Consalter; Orlando Durán; André J. Souza

Addresses: School of Engineering and Architecture, University of Passo Fundo, Passo Fundo, Brazil ' School of Engineering and Architecture, University of Passo Fundo, Passo Fundo, Brazil ' Pontificia Universidad Católica de Valparaíso, Avenida Los Carrera 01567, Quilpué, Chile ' Department of Mechanical Engineering, Federal University of Rio Grande do Sul, Porto Alegre, Brazil

Abstract: This study investigates the behaviours of machining forces and the roughness of a workpiece in the dry turning of AISI 4140 steel hardened at 55 HRC due to the wear evolution of a mixed ceramic tool with 'S'-type blade microgeometry. Six end-of-life tests were performed by combining three levels of cutting speed and two feed rate levels. A constant depth of cut was maintained. According to the results, the highest cutting speed and feed rates had a significant effect on the flank and crater wear of the tool and gradually changed the values of the forces and roughness. The feed rate was the parameter with the highest effect on the output parameters of the process. The crater wear evolution caused a reduction of the machining forces. Meanwhile, flank wear formation promoted an increase in the machining force components. From the point of view of the influence of tool wear processes, and, unlike what happens with flank wear, the crater formation affects favourably the surface roughness, as its evolution promoted the reduction of the R_a values in all cutting conditions.

Keywords: tool wear; cutting forces; ceramic tool microgeometry; surface roughness; turning of hardened steel.

DOI: 10.1504/IJMMM.2019.099490

International Journal of Machining and Machinability of Materials, 2019 Vol.21 No.3, pp.228 - 243

Received: 08 Aug 2017
Accepted: 03 Mar 2018
Published online: 07 May 2019 *

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Title: Effect of wear progression in an 'S'-type mixed ceramic tool on machining forces and surface roughness in the turning of hardened AISI 4140 steel

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