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Title: PCBN Tool Insert Wear Behavior Investigation and Optimization of Cutting Parameters when Hard Turning Hardened 42CrMo4 Steel
Authors: Musonda Emmanuel Kabaso ; Chen Yongjie
DOI:
Aff: Huazhong University of Science and Technology, School of Mechanical Science and Engineering, 1037 Luo Yu Road, Wuhan, Hubei 430074, P. R. China
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Keywords: Hard Turning; Tool Life; PCBN; Optimization; Taguchi Method
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Abstract:Background: Better usage of polycrystalline cubic boron nitride (PCBN) turning tools can effectively be realized with a detailed understanding of PCBN tool wear patterns and models. Individual cutting parameter influences on the general tool wear patterns were quantitatively evaluated on the basis of appropriate physical and mathematical modeling approaches. Optimal turning parameters (cutting speed and feed rate) based on the Taguchi method to minimize surface roughness, cutting force and tool wear and to maximize tool life were selected. Objective: The goal of this experimental analysis was to observe the behavior of a PCBN tool during hard turning of ChromiumMolybdenum Alloy Steel (42CrMo4) to add empirical experimental data in this field to advance the use of PCBN cutting tools in industry. This is because in most cases the practicality of hard turning using a PCBN tool for a specific hard turning application requires experimental evidence for it to gain industrial application. Results: The outcomes indicated that PCBN tool suggests good wear resistance regardless of the aggressiveness of the 42CrMo4 at 62HRC. Even when the tool wear VB reached 0.3 mm, the majority of the recorded Ra values did not exceed 1 micrometer at the various speeds tested. ANOVA results indicated that feed rate had more effect than the cutting speed on the tool life, tool wear and surface roughness. Conclusion: The correlation of tool wear VB and surface roughness Ra established allows obtaining experimental empirical data on the cutting tool wear from measured surface roughness for practical use in industry. In addition, using appropriate combinations of speed and feed rate allows successful use of PCBN tools to machine hard materials with satisfactory results comparable to grinding and to economically prolong tool life.