切削刃的幾何形狀，工件的硬度的影響，進給速度和切削速度對表面粗糙度和力量完成硬化aisi h13鋼的車削畢業(yè)課程設(shè)計外文文獻翻譯、中英文翻譯、外文翻譯

1、<p>　　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</p><p>　　Tugrul Özel, Tsu-Kong Hs

2、u, Erol Zeren </p><p>　　Department of Industrial and Systems Engineering Rutgers, The State University of New Jersey, New Jersey 08854 USA</p><p><b>　　Abstract</b></p><p&g

3、t;　　In this study, effects of cutting edge geometry, workpiece hardness, feed rate and cutting speed on surface roughness and resultant forces in the finish hard turning of AISI H13 steel were experimentally investigated

4、. Cubic boron nitrite inserts with two distinct edge preparations and through-hardened AISI H-13 steel bars were used. Four factor (hardness, edge geometry, feed rate and cutting speed)- two level fractional experiments

5、were conducted and statistical analysis of variance was performe</p><h2>　　1. INTRODUCTION </h2><p>　　Hard turning, machining ferrous metal parts that are hardened usually between 45-70 HRC, can

6、 be performed dry using polycrystalline cubic boron nitride (PCBN, commonly CBN) cutting tools as extensively reported in literature [1-8]. Research results in the literature concerning mechanism of serrated chip formati

7、on in order to relate process characteristics and stability of cutting to the chip shapes during hard turning [9-19]. Other research concerning with composition, temperatures and wear char</p><p>　　Cutting t

8、ool geometry and material properties</p><p>　　Hard turning with CBN cutting tools demands prudent design of tool geometry. CBN cutting tools have lower toughness than other common tool materials, thus chippi

9、ng ismore likely [2]. Therefore, a nose radius and proper edge preparation are essential to increase the strength of cutting edge and attain favorable surface characteristics on finished metal components [23]. CBN cuttin

10、g tools designed for hard turning feature negative rake geometry and edge preparation (a chamfer or a hone, or even bot</p><p>　　Fig. 1. A flow chart illustrating relationships of factors in hard turning.<

11、;/p><p>　　Theile et al. [24, 25], presented research results of an experimental investigation of effects of cutting edge geometry and workpiece hardness on residual stresses in finish hard turning of AISI 52100

12、 steel. They indicated that both factors are significant for the surface integrity of finish hard turned components. Specifically, they showed that large hone radius tools produce more compressive stresses, but also leav

13、e “white-layers”. Özel [26] investigated the influence of edge geometry in CBN t</p><p>　　Fig. 2. Type of edge preparations for CBN cutting tools.</p><h4>　　1.2 Workpiece hardness </h2&g

14、t;<p>　　Due to the changes in properties of hardened workpiece material, basic shearing process and formation of chips differ in hard turning [5]. Prior research showed that workpiece hardness has a profound effec

15、t on the performance of the CBN tools [1,2,8] and also integrity of finish machined surfaces [23,25]. Matsumoto et al. [23] and Thiele et al. [25] studied the effect of workpiece hardness on residual stresses. In a recen

16、t study, Guo and Liu [27] investigated material properties of hardened AISI</p><h4>　　1.3 Cutting speed, feed rate and depth of cut </h2><p>　　Performance of CBN cutting tools is highly dependen

17、t on the cutting conditions i.e. cutting speed, feed, feed-rate, and depth of cut [7]. Especially cutting speed and depth of cut significantly influence tool life [22]. Increased cutting speed and depth of cut result in

18、increased temperatures at the cutting zone. Since CBN is a ceramic material, at elevated temperatures chemical wear becomes a leading wear mechanism and often accelerates weakening of cutting edge, resulting in premature

19、 tool fai</p><h4>　　1.4 Surface integrity, residual stresses and tool wear </h2><p>　　In general, residual stresses become more compressive as workpiece hardness increases. The hardness and frac

20、ture toughness of CBN tools decrease with reduced CBN content [8]. Owing to ceramic binder phase, CBN-L tools have a lower thermal conductivity, which causes increasing temperatures of cutting edge during hard turning. C

21、hou and Barash [9] reported that CBN-L tools are more suitable for finish turning of hardened steel. At low cutting speeds, tool life of CBN-L is superior to CBN-H, whereas</p><h4>　　1.5 Accuracy and rigidit

22、y of the machine tool </h2><p>　　Another parameter that is often ignored is tool vibration. In order to reduce tool vibration it is necessary provide sufficiently rigid tool and workpiece fixtures. Assuring

23、that there is minimal tool vibration is an easy way to improve surface roughness. It is also necessary that the tooling system be extremely rigid to withstand the immense cutting forces. It is well known that the radial

24、force is the largest among force components during hard turning. Many researchers indicated that extremely</p><p>　　To improve the overall efficiency of finish hard turning, it is necessary to have a complet

25、e process understanding. To this end, a great deal of research has been performed in order to quantify the effect of various hard turning process parameters to surface quality. In order to gain a greater understanding of

26、 the hard turning process it is necessary to understand the impact of each of these variables, but also the interactions between them. It is impossible to find all of the variables that imp</p><h2>　　2. EXPE

27、RIMENTAL PROCEDURE </h2><h4>　　2.1 Workpiece material </h2><p>　　The workpiece material used in this study was AISI H13 hot work tool steel, which is used for high demand tooling. The cylindrica

28、l bar AISI H13 specimen that are utilized in this experiments had a diameter of 1.25 inches and length of 2 feet. The bar specimens were heat treated (through-hardened) at in-house heat treatment facility in order to obt

29、ain the desired hardness values of 50 and 55 HRC. However, the subsequent hardness tests by using Future Tech Rockwell type hardness tester revealed th</p><h4>　　2.2 Tooling and edge geometry </h2>&l

30、t;p>　　CBN inserts with two distinct representative types of edge preparations were investigated in this study. These edge preparations include: a) “chamfered” (T-land) edges and b) “honed” edges as illustrated in Fig.

31、2. Solid top CBN inserts (TNM-433 and GE Superabrasives BZN 8100 grade) inserts were used with a Kennametal DTGNR-124B right hand tool holder with 00 lead and –50 rake angles. Honed and chamfered insert edge geometry wer

32、e measured in coordinated measurement machine with three replications</p><h4>　　2.3 Experimental design </h2><p>　　A four factor – two level factorial design was used to determine the effects of

33、 the cutting edge geometry, workpiece hardness, feed rate and cutting speed on surface roughness and resultant forces in the finish hard turning of AISI H 13 steel. The factors and factor levels are summarized in Table 1

34、. These factor levels results in a total of 16 unique factor level combinations. Sixteen replications of each factor level combinations were conducted resulting in a total of 256 tests. Each replicatio</p><p&g

35、t;　　Longitudinal turning was conducted on a rigid, high-precision CNC lathe (Romi Centur 35E) at a constant depth of cut at 0.254 mm. The bar workpieces were held in the machine with a collet to minimize run-out and maxi

36、mize rigidity. The length of cut for each test was 25.4 mm in the axial direction. Due to availability constraints, each insert were used for one factor level combination, which consisted of 16 replications. (A total of

37、three honed and three chamfer inserts were available). In this m</p><h4>　　2.4 Cutting force measurements </h2><p>　　The cutting forces were measured with a three-component force dynamometer (Ki

38、stler Type 9121) mount on the turret disk of the CNC lathe via a custom designed turret adapter (Kistler type 9121) for the toolholder creating a very rigid tooling fixture. The charge signal generated at the dynamometer

39、 was amplified using charge amplifiers (Kistler Type 5814B1). The amplified signal is acquired and sampled by using data acquisition PCMCIA card and Kistler DyanoWare software on a laptop computer at a s</p><p

40、>　　Fig. 3. Measured cutting-force components.</p><p>　　3. RESULTS AND DISCUSSION </p><p>　　An analysis of variance (ANOVA) was conducted to identify statistically significant trends in the me

41、asured surface roughness and cutting force data. Separate ANOVA analyses were conducted for Ra surface roughness values and for each component of the cutting force i.e. axial (feed), radial (thrust), and tangential (cutt

42、ing) forces. Additionally, plots of significant factors corresponding to each ANOVA analysis were constructed. These plots provide a more in-depth analysis of the significant facto</p><p>　　3.1 ANOVA results

43、 </p><p>　　ANOVA tables for Ra surface roughness parameters are given in Table 2. In addition to degree of freedom (DF), mean square (MS) and F values (F) the table shows the P-values (P²) associate wit

44、h each factor level and interaction. A low P-value indicates an indication of statistical significange for the source on the response. Table 2 show that the main effects of edge geometry, cutting speed and feed rate exce

45、pt hardness, interactions between edge geometry and hardness, feed rate, and cutting spee</p><p>　　The radial force is usually the largest, tangential force is the middle and the axial (feed) force is the sm

46、allest in finish hard turning. In general, cutting force components are influences by cutting speed, edge geometry and feed rate. Tables 3-5 are ANOVA tables corresponding to the radial, axial (feed force) and tangential

47、 components of the cutting force, respectively. These tables show that the main effects of workpiece hardness, the edge geometry, cutting speed and feed rate (except for ax</p><p>　　Table 3 shows that the ma

48、in effects of the edge geometry, cutting speed, hardness and the interactions between edge geometry and hardness, cutting speed, feed rate are significant with respect to the forces in the axial (feed) direction. Axial (

49、feed) force is not much influence by the change in feed rate. </p><p>　　Table 4 shows that the main effects of the edge geometry, cutting speed, hardness and only the interactions between edge geometry and c

50、utting speed, feed rate are significant with respect to the forces in the radial direction.</p><p>　　Table 5 shows that the main effects of the edge geometry, cutting speed, hardness, feed and only the inter

51、actions between edge geometry and hardness, cutting speed, feed rate are significant with respect to the forces in the tangential direction.</p><p>　　3.2 Effect of feed rate and edge preparation on surface r

52、oughness </p><p>　　Graphs of Ra surface roughness parameters are shown in Figures 4 and 5. These figures have been constructed to illustrate the main effects of edge geometry and feed rate parameters on the

53、surface roughness. Based on the previous analysis, the main effect of the interaction between edge geometry and feed rate are found to be statistically significant on surface roughness Ra. Fig. 4 shows the effect of edge

54、 geometry and feed rate on the Ra surface roughness parameter for 54.7 HRC, cutting speed 20</p><p>　　Fig. 4. Effect of cutting edge geometry and feed rate on surface roughness (high levels).</p><

55、p>　　Fig. 5. Effect of cutting edge geometry and feed on surface roughness (low levels).</p><p>　　These two figures show that all edge preparations are confounded at the lowest feed rate (0.05mm/rev). Howe

56、ver, the large edge radius resulted in better surface roughness when higher hardness and cutting speed selected, whereas it is the opposite when lower hardness and cutting speed selected. Finally, it should be noted that

57、 the main effect due to feed is readily apparent for each edge preparation. Specifically, the surface roughness increases as the feed rate increases as the surface roughness</p><h4>　　3. 3 Effect of surface

58、hardness and edge preparation on surface roughness </h2><p>　　Fig. 6 is constructed to illustrate the main effects of edge geometry and surface hardness parameters on the surface roughness with cutting speed

59、 200 m/min, feed rate 0.2 mm/rev and cutting length 406.4 mm. Based on the previous analysis, the main effect of the interaction between edge geometry and workpiece surface hardness are statistically significant to surfa

60、ce roughness Ra parameters. The figure shows that small edge radius and lower workpiece surface hardness resulted in better surface rou</p><p>　　Fig. 6. Effect of cutting edge geometry and hardness on surfac

61、e roughness.</p><h4>　　3.4 Effect of surface hardness and edge preparation on tangential, radial and axial (feed) forces </h2><p>　　Graphs of the force components as functions of edge geometry a

62、nd workpiece surface hardness are shown in Figs. 7-9. These figures show that chamfered edge geometry and higher workpiece surface hardness result in higher tangential and radial forces but not in axial (feed) force. Add

63、itionally, small honed radius edge geometry results in higher forces in the axial (feed) directions. </p><p>　　Fig. 7: Effect of cutting edge geometry and surface hardness on tangential force.</p><

64、;p>　　Fig. 8: Effect of cutting edge geometry and surface hardness on radial force.</p><p>　　Fig. 9: Effect of cutting edge geometry and surface hardness on axial force.</p><h4>　　3.5 Effect o

65、f cutting speed and cutting edge geometry on tangential force </h2><p>　　Fig. 10 is obtained to illustrate the main effects of edge geometry and cutting speed parameters on tangential force. Based on the pre

66、vious analysis, the main effect of the edge geometry and cutting speed are statistically significant to tangential force. Fig. 10 shows that higher cutting speed and smaller edge radius resulted in lower tangential force

67、. </p><h4>　　3.6 Effect of cutting speed and feed rate on tangential force </h2><p>　　Fig. 11 is obtained to illustrate the main effects of cutting speed and feed rate parameters on tangential f

68、orce. Based on the previous analysis, the interaction of cutting speed and feed rate are statistically significant to tangential force. Fig. 11 shows that lower cutting speed and lower feed rate resulted in lower tangent

69、ial force.</p><p>　　Fig. 10 Effect of cutting speed and cutting edge geometry on tangential force.</p><p>　　Fig. 11. Effect of cutting speed and feed rate on tangential force.</p><h2&

70、gt;　　4. CONCLUSIONS </h2><p>　　In this study, a detailed experimental investigation is presented for the effects of cutting edge preparation geometry, workpiece surface hardness and cutting conditions on the

71、 surface roughness and cutting forces in the finish hard turning of AISI H13 steel. The results have indicated that the effect of cutting edge geometry on the surface roughness is remarkably significant. The cutting forc

72、es are influenced by not only cutting conditions but also the cutting edge geometry and workpiece surfac</p><p>　　This study shows that the effects of workpiece hardness, cutting edge geometry, feed rate and

73、 cutting speed on surface roughness are statistically significant. The effects of two-factor interactions of the edge geometry and the workpiece hardness, the edge geometry and the feed rate, and the cutting speed and fe

74、ed rate are also appeared to be important. Especially, small edge radius and lower workpiece surface hardness resulted in better surface roughness. Cutting edge geometry, workpiece hardne</p><p>　　5.ACKNOWLE

75、DGMENTS </p><p>　　Authors would like to acknowledge Mr. Joseph Lippencott and Talat Khaireddin for their assistance in conducting experiments.</p><h2>　　REFERENCES </h2><p>　　1. N.

76、Narutaki, Y. Yamane, “Tool wear and cutting temperature of CBN tools in machining of hardened steels”, Annals of the CIRP, Vol. 28/1, 1979, pp. 23-28. </p><p>　　2. T. Hodgson, P.H.H. Trendler, G. F. Michelle

77、tti, “Turning hardened tool steels with Cubic Boron Nitride inserts”, Annals of CIRP, Vol. 30/1, 1981, pp. 63-66. </p><p>　　3. W. Koenig, R. Komanduri, H. K. Toenshoff, G. Ackeshott, “Machining of hard metal

78、s”, Annals of CIRP, Vol.33/2, 1984, pp. 417-427 </p><p>　　4. W. Koenig, M. Klinger, “Machining hard materials with geometrically defined cutting edges –Field of applications and limitations”, Annals of CIRP,

79、 Vol. 39/1, 1990, pp. 61-64. </p><p>　　5. W. Koenig, A. Berktold, F. Koch, “Turning versus grinding – a comparison of surface integrity aspects and attainable accuracies”, Annals of the CIRP, Vol.42/1, 1993,

80、 pp. 39-43. </p><p>　　6. F. Klocke, G. Eisenblatter, “Dry cutting”, Annals of the CIRP, Vol.46/2, 1997, pp. 519-526. </p><p>　　7. H. K. Toenshoff, C. Arendt, R. Ben Amor, “Cutting hardened steel

81、”, Annals of the CIRP, Vol. 49/2, 2000, pp. 1-19. </p><p>　　8. Y. S. Chou, M. M. Barash, “Review on hard turning and CBN cutting tools”, SME Technical Paper, Proceedings of 1st International Machining and Co

82、nference, MR95-214, 1995, pp. 951-962. </p><p>　　9. Y. Matsumoto, M. M. Barash, C. R. Liu, “Cutting mechanism during machining of hardened steel”, Material Science and Technology, Vol.3, 1987, pp.299-305. &l

83、t;/p><p>　　10. M. C. Shaw, A. Vyas, “Chip formation in the machining of hardened steel”, Annals of the CIRP, Vol.42/1, 1993, pp. 29-33. </p><p>　　11. M. A. Davies, Y. Chou, C. J. Evans, “On chip mo

84、rphology, tool wear and cutting mechanics in finish hard turning”, Annals of the CIRP, Vol.45/1, 1996, pp.77-82. </p><p>　　12. M. A. Elbestawi, A. K. Srivastava, T. I. El-Wardany, “A model for chip formation

85、 during machining of hardened steel”, Annals of the CIRP, Vol.45/1, 1996, pp. 71-76. </p><p>　　13. V. P. Astakhov, S.V. Shvets, M.O.M. Osman, “Chip structure classification based on mechanism of its formatio

86、n”, Journal of Materials Processing and Technology, Vol. 71, 1997, pp. 247-257.</p><p>　　切削刃的幾何形狀，工件的硬度的影響，進給速度和切削速度對表面粗糙度和力量完成硬化AISI H13鋼的車削</p><p>　　Tugrul Ozel津，港許，埃羅爾Zeren</p><p&g

87、t;　　工業(yè)及系統(tǒng)工程羅格斯，新澤西州立大學，新澤西州08854美國</p><p><b>　　摘要</b></p><p>　　在這項研究中，切削刃的幾何形狀，工件的硬度的影響，實驗研究了進給速度和切削速度對表面粗糙度和在完成硬車削AISI H13鋼合力。準備在立方氮化硼鋼筋插入兩個不同的亞硝酸鹽，通過硬化采用AISI H 13進行研究。四個因素（硬度，邊緣幾何，

88、進給率和切削速度），兩級分數(shù)實驗進行統(tǒng)計分析和方差計算。在硬車削實驗中，三面組成部分作用力的工具加工和粗糙度的變化。這項研究表明，影響工件的硬度，切削刃的幾何形狀，進給率和切削速度對表面粗糙度有明顯差異性。進給速度的切割速度和效果的兩個因素相互作用的邊緣幾何形狀和工件硬度，邊緣幾何形狀和進給速度顯得很重要。尤其是小邊半徑，降低工件表面硬度可導致有更好的表面粗糙度。尖端的幾何形狀，工件硬度和切削速度被視為最具影響力的構(gòu)件。工件表面硬度較低

89、、小半徑有較低的邊緣切向和徑向力。</p><p><b>　　1.簡介 </b></p><p>　　硬車削，加工硬化45-70 HRC通常在有色金屬零件，可進行干聚晶立方氮化硼（PCBN刀具，CBN刀具常用）在文獻[1-8]廣泛報道。研究結(jié)果在有關(guān)文獻的鋸齒形切屑的形成以與工藝特點和切削的切屑形狀硬車削[ 19 ]中的穩(wěn)定性機制。其他有關(guān)成分的研究，溫度和CBN刀

90、具1,8,20,21,22,28 ]和[影響工作的材料特性的磨損特性，刀具的幾何形狀和切削條件對表面完整性的完成加工的零件[ 23 ]表明，硬車削的挑戰(zhàn)和識別各種工藝，設(shè)備和工裝的相關(guān)因素影響表面質(zhì)量，刀具壽命和生產(chǎn)率。通過文獻回顧，影響力，刀具磨損/故障和粗糙度和完整的成品的表面，在硬車削用CBN刀具和它們的相互影響與圖1所示的圖表說明。在本圖中，以上參數(shù)水平虛線為因素或輸入到硬車削過程，他們只能選擇在開始的時候，除了刀具振動。所有其

91、他參數(shù)，位于下面的虛線，認為是性能的措施或輸出的硬車削過程。的文獻回顧顯示，在圖表中，幾乎所有的因素，給出了硬車削工藝性能的影響。這些因素可分為如下：</p><p>　　刀具幾何形狀和材料特性</p><p>　　選擇CBN刀具硬車削刀具幾何參數(shù)是要慎重考慮設(shè)計要求。CBN刀具的韌性比其他常見的刀具材料低，因此切削更有可能[ 2 ]。因此，刀尖半徑和適當?shù)倪吘壷苽涫翘岣咔邢魅械膹姸龋_到

92、良好的表面特性對加工的金屬部件[ 23 ]必不可少。立方氮化硼刀具設(shè)計的硬車削特征負前角的幾何形狀和邊界的制備（斜面或骨，或兩者）。制備的邊緣設(shè)計規(guī)范往往是經(jīng)過廣泛的實驗確定。圖2顯示了邊緣CBN刀具普通制劑的類型。根據(jù)最近的研究，這是顯而易見的，對表面質(zhì)量的邊緣的幾何效應顯著[ 23 ]。</p><p>　　圖1 .一個因素流程圖的切削關(guān)系</p><p>　　泰勒等人[ 24，25

93、]的切削刃的幾何形狀和工件的硬度實驗表明，在完成硬車削AISI 52100鋼的殘余應力影響的實驗研究結(jié)果。他們表示，這兩個因素是顯著的完成硬表面完整性轉(zhuǎn)向組件。具體地說，他們指出大磨練半徑工具產(chǎn)生更多的壓應力，但也留下“白層”。Ö采爾[ 26 ]研究了應力和溫度的發(fā)展通過有限元模擬硬車削在CBN刀具刃的幾何形狀的影響。Chou等人。[ 28 ]實驗研究了影響CBN含量對表面質(zhì)量和刀具磨損的硬化AISI 52100鋼工具。本文的

94、研究結(jié)論表明，低含量CBN工具產(chǎn)生的高含量CBN刀具和切削深度更好的表面粗糙度對刀具磨損率的影響較小。</p><p>　　圖2.預置型號的邊緣CBN刀具</p><p><b>　　1.2 工件硬度</b></p><p>　　由于在性質(zhì)上的變化對硬工件材料,基本的剪切過程,形成不同的硬車削芯片[5]。先前的研究表明,工件硬度的方方面面有深遠

95、的影響CBN刀具的性能并完成的加工面。已有許多科學家(23)和泰勒等科學家[25]研究了工件硬度的影響對殘余應力。在最近的一項研究中,郭和劉[27]研究了材料的性能對硬AISI 52100軸承鋼使用溫度控制拉伸試驗和正交切削試驗,論證了硬度材料的性能在很大程度上影響了占流動應力性質(zhì)的巨大變化。</p><p>　　1.3切削速度、進給速率和切削深度</p><p>　　CBN刀具性能的高度

96、依賴切割條件即切削速度、切削率和切削深度。尤其是切削速度、切削深度明顯影響刀具壽命。提高切削速度、切削深度導致切削區(qū)溫度的增加。自從CBN是在高溫陶瓷材料,化學因素就變成了一個領(lǐng)先的磨損機理和切削刃經(jīng)常加速減弱,導致早產(chǎn)(切削刀具的失效),即邊緣破損的刀具。此外,泰勒注意到當進給量增加時,殘余應力的變化,從抗壓抗拉。</p><p>　　1.4表面完整性，殘余應力和刀具磨損</p><p>

97、;　　一般來說,殘余應力作為工件硬度變得更加壓的增加而增加。而成,其硬度和韌性CBN刀具降低和減少立方氮化硼含量[8]。由于陶瓷黏結(jié)相,CBN-L工具會有較低的導熱系數(shù),進而導致在逐漸升高的氣溫中切削刃的硬轉(zhuǎn)彎。據(jù)巴拉什[9]報道,CBN-L工具比較適合完成的車削加工淬硬鋼。在低切削速度、刀具壽命的CBN-L優(yōu)于CBN-H,而在較高的切削速度,相反的意見是正確的,并且也表面粗糙度是較不有利的工具在使用CBN-H[28]。泰勒報道說,所產(chǎn)

98、生的殘余應力大邊緣磨練工具通常更抗壓比邊緣應力產(chǎn)生的小工具,他們也離開磨礪白層。此外,邊緣幾何的影響中起重要作用,工件的熱塑性變形。肯尼格報道,增加進給量提高抗壓殘余應力最大,加深影響區(qū)。也有人認為,不宜在條款的槽的表面光潔度相比可磨練或銳利的邊緣。</p><p>　　以全面提升效率,努力完成車削是有必要的,它擁有一個完整的過程的理解。為了達到這一目的,大量的研究工作被執(zhí)行了,為了定量研究了切削過程的影響參數(shù),