0
TECHNICAL PAPERS

Surface Integrity of Die Material in High Speed Hard Machining, Part 1: Micrographical Analysis

[+] Author and Article Information
T. I. El-Wardany, H. A. Kishawy, M. A. Elbestawi

Intelligent Machines and Manufacturing Research Centre, Department of Mechanical Engineering, McMaster University, Hamilton, Ontario, Canada, L8S 4L7

J. Manuf. Sci. Eng 122(4), 620-631 (Nov 01, 1999) (12 pages) doi:10.1115/1.1286367 History: Received November 01, 1997; Revised November 01, 1999
Copyright © 2000 by ASME
Your Session has timed out. Please sign back in to continue.

References

Bailey,  J. A., Jeelani,  S., and Becker,  S. E., 1976, “Surface Integrity in Machining AISI 4340 Steel,” Trans. ASME, J. Eng. Ind., 98/3, pp. 999–1006.
Field,  M., Koster,  W. P., Kohls,  J. B., Snider,  R. E., and Maranchic,  J., 1970, “Machining of High Strength Steels With Emphasis on Surface Integrity,” Technical Report AFML-TR-70-11, Air Force Material Laboratory, MATF, Wright-Patterson Air Force Base, Ohio.
Field,  M., and Kahles,  J., 1971, “Review of Surface Integrity of Machined Components,” Ann. CIRP, 20/2, pp. 153–163.
Brinksmeier,  E., Cammett,  J., Konig,  W., Leskovar,  P., Peters,  J., and Tonshoff,  H. K., 1982, “Residual Stresses-Measurement and Causes in Machining Processes,” Ann. CIRP, 31/2, pp. 491–510.
Leskovar,  P., and Peklenik,  J., 1982, “Influences Affecting Surface Integrity in the Cutting Process,” Ann. CIRP, 31/1, pp. 447–450.
Bailey,  J. A., 1974, “On Surface Damage During Machining of AISI 4340 Steel,” Wear, 27, pp. 161–173.
Matsumoto,  Y., Barash,  M. M., and Liu,  C. R., 1986, “Effect of Hardness on the Surface Integrity of AISI 4340 Steel,” Trans. ASME, J. Eng. Ind., 108/3, pp. 169–175.
Tönshoff,  H. K., Wobker,  H. G., and Brandt,  D., 1995, “Tribological Aspects of Hard Turning with Ceramic Tools,” J. Soc. Tribol. Lubr. Eng., 51/2, pp. 163–168.
Tönshoff,  H. K., Wobker,  H. G., and Brandt,  D., 1995, “Hard Turning-Influences on the Workpiece Properties,” Trans. NAMRI/SME, XXIII, pp. 215–220.
Chou, Y. K., and Evans, C. J., 1996, “Microstructural Effects in Precision Hard Turning,” Proc. Of Int. Mech. Eng. Congress and Exposition, ASME Winter Annual Meeting, Manuf. Sci. Eng. ASME, MED-4 , pp. 237–242.
Ogata, M., 1989, “Einsatz von PCBN-Werkzeugen in der Produktion,” VDI Berichte, No. 762, pp. 271–279.
König,  W., Komanduri,  R., Tonshoff,  H. K., and Ackershott,  G., 1990, “Machining of Hard Materials,” Ann. CIRP,39/1, pp. 417–427.
König,  W., Berktold,  A., and Koch,  K. F., 1993, “Turning Versus Grinding-A Comparison of Surface Integrity Aspects and Attainable Accuracies,” Ann. CIRP,42/1, pp. 39–43.
El-Wardany, T. I., Elbestawi, M. A., Attia, M. H., , and Mohammed, E., 1992, “Surface Finish Characteristics in Turning of Hardened Steel,” Proc. Of Int. Mech. Eng. Congress and Exposition, ASME Winter Annual Meeting, Symp. On Engineered Surfaces, PED. 62 , pp. 146–160.
El-Wardany, T. I., Mohammed, E., and Elbestawi, M. A., 1993, “Material Side Flow in Finish Turning of Hardened Steel with Ceramic Tools,” Proc. Of Int. Mech. Eng. Congress and Exposition, ASME Winter Annual Meeting, PED- 67 /TRIB- 4 , pp. 159–170.
Abráo, A. M., Wise, M. L. H., and Aspinwall, D. K., 1995, “Tool Life and Workpiece Surface Integrity Evaluations When Machining Hardened AISI H13 and AISI E52100 Steels With Conventional Ceramic and PCBN Tool Materials,” NAMRC XXIII Conference, May 24–26, Houghton, Michigan, MR95-195.
Bresseler, B., El-Wardany, T. I., and Elbestawi, M. A., 1997, “Material Side Flow in High Speed Finish Boring of Case Hardened Steel,” 1st French and German Conference on High Speed Machining, June 17–18, Metz, France.
Ikeda, T., Takahashi, I, Matsuoka, T., and Nakagawa, T., 1992, “Ultra High Speed Milling of Die Steel with Ball-nose End Mill,” Proc. 2nd Int. Conf. On Die and Mould Technology, Singapore, Sept., pp 48–56.
Rigby, P., 1993, “High Speed Milling in the Mould and Die Making Industries,” Diamond and CBN Ultra Hard Materials Symposium-93, Ontario, Canada.
Elbestawi,  M. A., Chen,  L., Becze,  C. E., and El-Wardany,  T. I., 1997, “High Speed Milling of Dies and Moulds in their Hardened State,” Ann. CIRP, 46/1, pp. 57–62.
Poggie, R. A. and Wert, J. J., 1991, “The Influence of Surface Finish and Strain Hardening on Near Surface Residual Stress and the Friction and Wear Behavior of A2, D2 and CPM-10V Tool Steels,” Wear of Materials, ASME, pp. 497–501.
Prevey,  P. S., 1986, “A Method of Determining the Elastic Properties of Alloys in Selected Crystalographic frictions for X-Ray Diffraction Residual Stress Measurement,” Adv. X-Ray Anal., 20, pp. 345–354.
Koistinen,  D. P., and Maburger,  R. E., 1959, “A Simplified Procedure for Calculating Peak Position in X-Ray Residual Stress Measurements on Hardened Steel,” Trans. ASME, 51, pp. 537–550.
Moore,  M. G., and Evans,  W. P., 1958, “Mathematical Correction for Stress in Removal layers in X-Ray Diffraction Residual Stress Analysis,” Trans. SAE,66, pp. 340–345.
Kishawy, H. A., and Elbestawi, M. A., 1998, “Effects of edge Preparation and Cutting Speed on Surface Integrity of Die Materials in Hard Machining,” Proc. Of Int. Mech. Eng. Congress and Exposition, MED-8 , pp. 269–276.
Oishi,  K., 1995, “Built-up Edge Elimination in Mirror Cutting of Hardened Steel,” Trans. ASME, J. Eng. Ind., 117/1, pp. 62–66.
Kishawy, H. A., and Elbestawi, M. A., 1997 “Effect of Process Parameters on Chip Formation when Machining Hardened Steel,” Int. Mech. Eng. Congress and Exposition, ASME-MED 6-2 , Dallas, Texas, pp. 13–20.
Elbestawi,  M. A., Srivastava,  A. K., and El-Wardany,  T., 1996, “A Model for Chip Formation During Machining of Hardened Steel,” Ann. CIRP,45/1, pp. 71–76.
Eyre,  T. S., and Baxter,  A., 1972, “The Formation of White Layers at Rubbing Surfaces,” Tribology, 12, pp. 256–261.
Roberts, G. A., Hamaker, Jr., J. C. and Johnson, A. R., 1962, Tool Steels, The American Society for Metals, 3rd edition, Metals, Park, Ohio.
Gill, J. P., Rose, R. S., Roberts, G. A., Johnstin, H. G., and George, R. B., 1944, Tool Steels, The American Society for Metals, Cleveland, Ohio.

Figures

Grahic Jump Location
Micrographs of longitudinal mid-section of chips produced by a sharp tool (V=350 m/min,f=0.1 mm/rev,d=0.4 mm,r=1.2 mm, chamfered edge 20°/0.1 mm)
Grahic Jump Location
Micrographs of longitudinal mid-section of chips produced by a worn tool (V=350 m/min,f=0.4 mm/rev,d=0.4 mm,r=1.2 mm, chamfered edge 20°/0.1 mm)
Grahic Jump Location
SEM images of mid-section of chips produced by a tool with 0.5 mm flank wear (V=350 m/min,f=0.1 mm/rev,d=0.4 mm,r=1.2 mm, chamfered edge 20°/0.1 mm)
Grahic Jump Location
Micrographs of chips mid-section produced by tools with flank wear of 0.2 mm (V=350 m/min,f=0.1 mm/rev,r=1.2 mm, chamfered edge 20°/0.1 mm)
Grahic Jump Location
Effect of cutting conditions and tool wear on workpiece surface profile (V=350 m/min,r=1.2 mm, chamfered edge 20°/0.1 mm)
Grahic Jump Location
SEM images of surfaces produced by sharp and worn tools (V=350 m/min,r=1.2 mm, chamfered edge 20°/0.1 mm)
Grahic Jump Location
SEM images of the subsurface layer (V=350 m/min.,f=0.05 mm/rev.,d=0.4 mm,r=1.2 mm, chamfered edge 20°/0.1 mm)
Grahic Jump Location
SEM images of the unetched and etched subsurface layer (V=350 m/min,r=1.2 m, chamfered edge 20°/0.1 mm)
Grahic Jump Location
SEM images of subsurface microstructure (V=350 m/min,f=0.1 mm/rev.,r=1.2 mm, chamfered edge 20°/0.1 mm)
Grahic Jump Location
SEM images showing severe plastic deformation beneath the machined surface (V=350 m/min,r=1.2 mm, chamfered edge 20°/0.1 mm)
Grahic Jump Location
SEM images of the subsurface microstructure (V=350 m/min,f=0.1 mm/rev.,r=1.2 mm, chamfered edge 20°/0.1 mm)

Tables

Errata

Discussions

Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In