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Research Papers

Impact of the Heat Treatment Condition of Steel AISI 4140 on Its Frictional Contact Behavior in Dry Metal Cutting

[+] Author and Article Information
Stefan Buchkremer

Laboratory for Machine Tools and
Production Engineering (WZL),
RWTH Aachen University,
Steinbachstrasse 19,
Aachen 52074, Germany
e-mail: s.buchkremer@wzl.rwth-aachen.de

Fritz Klocke

Laboratory for Machine Tools and
Production Engineering (WZL),
RWTH Aachen University,
Steinbachstrasse 19,
Aachen 52074, Germany
e-mail: f.klocke@wzl.rwth-aachen.de

Benjamin Döbbeler

Laboratory for Machine Tools and
Production Engineering (WZL),
RWTH Aachen University,
Steinbachstrasse 19,
Aachen 52074, Germany
e-mail: b.doebbeler@wzl.rwth-aachen.de

Manuscript received February 11, 2016; final manuscript received April 12, 2016; published online July 25, 2016. Assoc. Editor: Laine Mears.

J. Manuf. Sci. Eng 138(12), 121006 (Jul 25, 2016) (11 pages) Paper No: MANU-16-1105; doi: 10.1115/1.4033447 History: Received February 11, 2016; Revised April 12, 2016

In this work, the impact of the heat treatment condition of steel AISI 4140 on its frictional contact behavior with coated cemented carbide and cubic boron nitride (CBN) in dry metal cutting is experimentally investigated. Two different kinds of tests were performed. The frictional behavior was investigated under conditions very similar to metal cutting on a frictional test bench, which was installed on a broaching machine. Additionally, orthogonal cutting processes with linear workpiece geometries were conducted on the same machine. The cutting experiments included observations of cutting forces, high-speed filming of chip formation, chip thickness ratio analysis as well as a comprehensive metallographic characterization of the chips and workpiece surfaces. The impacts of the undeformed chip thickness and cutting speed were investigated individually for coated cemented carbide and CBN as cutting materials. The frictional examinations delivered the Coulomb friction coefficients for all four combinations of work and cutting materials as a function of the relative velocity. The identified frictional behaviors explain the dependencies of forces, chip thicknesses, and surface microstructures on the tool and process conditions during the cutting tests.

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References

Figures

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Fig. 1

Optical micrographs of cross sections of heat treated specimen of AISI 4140

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Fig. 2

Broaching machine, which was used for frictional tests and orthogonal cutting experiments

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Fig. 3

Experimental setup of frictional tests [10]

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Fig. 4

Experimental setup of orthogonal cutting tests

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Fig. 5

Geometries and cutting materials of applied inserts

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Fig. 15

Results of orthogonal cutting experiments: microstructures of chip and workpiece surface for CBN as cutting material and normalized AISI 4140 as workmaterial

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Fig. 16

Results of orthogonal cutting experiments: microstructures of chip and workpiece surface for cemented carbide as cutting material and quenched/tempered AISI 4140 as work material

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Fig. 17

Results of orthogonal cutting experiments: microstructures of chip and workpiece surface for CBN as cutting material and quenched/tempered AISI 4140

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Fig. 18

Results of orthogonal cutting experiments: chip thickness ratios for coated cemented carbide as cutting material

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Fig. 14

Results of orthogonal cutting experiments: microstructures of chip and workpiece surface for cemented carbide as cutting material and normalized AISI 4140 as workmaterial

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Fig. 13

Results of orthogonal cutting experiments: high speed video footage for CBN as cutting material and quenched/tempered AISI 4140 as workmaterial

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Fig. 12

Results of orthogonal cutting experiments: high speed video footage for coated cemented carbide as cutting material and quenched/tempered AISI 4140 as workmaterial

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Fig. 11

Results of orthogonal cutting experiments: high speed video footage for CBN as cutting material and normalized AISI 4140 as workmaterial

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Fig. 10

Results of orthogonal cutting experiments: high speed video footage for coated cemented carbide as cutting material and normalized AISI 4140 as workmaterial

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Fig. 9

Results of orthogonal cutting experiments: cutting force components for CBN as cutting material

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Fig. 8

Results of orthogonal cutting experiments: cutting force components for cemented carbide as cutting material

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Fig. 7

Results of friction tests for CBN

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Fig. 6

Results of friction tests for coated cemented carbide

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Fig. 19

Results of orthogonal cutting experiments: chip thickness ratios for CBN as cutting material

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