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Experimental investigation of surface integrity in finish dry hard turning of hardened tool steel at different hardness levels

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Abstract

In this paper, the influences of cutting speed, depth of cut, feed, workpiece hardness (51, 55, 58, 62, and 65 ± 1 HRC), and nose radius on surface integrity in finish dry hard turning (FDHT) of the hardened tool steel AISI D2 by utilizing the polycrystalline cubic boron nitride (PCBN) inserts were experimentally investigated. Experimental results showed that the ploughing effect, serious squeeze, and elastic deformation have more significant on the surface roughness than those black fusion welding materials and side flows, and the surface roughness values are in the range of 0.34–0.86 μm between 150- and 301-m/min cutting speeds and totally attains a surface finish of grinding. The surface roughness is not very sensitive to the depth of cut in the range from 0.10 to 0.25 mm. The “residual cutting” materials, material plastic deformation, and even cohesion in the machined surface and cold welding effect do occur and hence influence on the surface integrity. The tiny grooves, severe plastic flow, and extensive material flows at lower feeds have significant influence on the surface integrity. The subsurface damages produced by the turning process also do occur and become severer at the larger feeds due to the localized stretch, plastic deformation, and even dilacerations of subsurface material induced by the friction from the tool flank face. The thermal softening, serious material side flows, and squeezing have significant effect on surface integrity when FDHT of the hardened tool steel AISI D2 at different hardness levels. And the heat effect is greater than the geometry effect as the nose radius attains a certain value.

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Author notes

  1. Linhu Tang, Chengxiu Gao & ** East Road, 730050, Lanzhou, Gansu Province, People’s Republic of China

Authors and Affiliations

  1. Provincial Key Laboratory for Green Cutting Technology and Application of Gansu Province (University), Lanzhou Institute of Technology, Lanzhou, People’s Republic of China

    Linhu Tang, Chengxiu Gao & **aojun Lin

  2. College of Mechano-Electronic, Lanzhou University of Technology, Lanzhou, 730050, Gansu Province, People’s Republic of China

    Jianlong Huang & Hao Shen

Authors
  1. Linhu Tang
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  2. Chengxiu Gao
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  3. Jianlong Huang
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  4. Hao Shen
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  5. **aojun Lin
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Correspondence to Linhu Tang.

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Tang, L., Gao, C., Huang, J. et al. Experimental investigation of surface integrity in finish dry hard turning of hardened tool steel at different hardness levels. Int J Adv Manuf Technol 77, 1655–1669 (2015). https://doi.org/10.1007/s00170-014-6484-1

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  • DOI: https://doi.org/10.1007/s00170-014-6484-1

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