Modares Mechanical Engineering

Modares Mechanical Engineering

Study of Surface Roughness, Topography, and Cutting Forces in Finish Turning of 1.1191 Hardened Steel Using Textured Cutting Tool

Document Type : Original Research

Authors
Mohammad Yazdani Khameneh
Mohsen Sadr
Amir Rasti
Mohammad Hossein Sadeghi
Tarbiat Modares University
10.22034/MME.24.1.31
Abstract
The effect of texturing the tool rake surface on the surface quality in hard turning of 1191/1 steel with a surface hardness of 45 HRC was studied in this research. The pattern parameters including, cavity diameter, pitch, and depth, as well as the pattern distance from the main cutting edge were changed in 3 levels, assuming the cutting tool with regular cavity texture. Nine tests were designed using the Taguchi DOE and conducted in dry and lubricated conditions with 2 repeats. Machining forces during the tests and surface roughness of the machined workpieces were measured in machining under lubricated and dry conditions. The results showed that in turning with a textured tool under lubrication, changing the parameters of the texture pitch and the distance from the cutting edge increased the surface roughness of the workpiece by 57.6% and 39.2%, respectively. This is while the increase in the diameter of the tissue cavity, due to the reduction of the contact area in the tool-chips interface and better lubrication near the cutting region, improved the surface roughness up to 40.7%. The cavities depth of also did not have a significant effect on improving lubrication and reducing the roughness of the final surface. In dry turning, increasing the cavities diameter in texture and decreasing the pattern pitch, reduced the surface roughness by 10.6% and 29%, respectively. Examining the SEM images also indicated the production of the workpiece surface with smoothed texture when turning using optimized textured tool.
Keywords
Tool Texture
Hard Turning
Lubricating
Surface integrity
Cutting forces

Subjects

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Modares Mechanical Engineering
Volume 24, Issue 1
December 2023
Pages 31-40