Dessoly, Vincent

Subbiah, Sathyan

Scholarly Materials And Research @ Georgia Tech

9/24/2004 Turning Hardened Steel Using Rotary Tool 1PMRC IAB MeetingOctober 15, 2003Turning Hardened Steel Using Rotary Tool• Graduate Research Assistants:Sathyan Subbiah, Ph.D candidateVincent Dessoly, M.S. student• Advisor:Dr. Shreyes N. Melkote, Associate Professor9/24/2004 Turning Hardened Steel Using Rotary Tool 2Overview1. Introduction2. Self-propelled rotary tools (SPRT)3. Surface integrity study4. Temperature prediction model5. Ongoing/Future work6. Conclusions9/24/2004 Turning Hardened Steel Using Rotary Tool 3IntroductionChallengesSituationConclusionsNext studiesTemperature modelSurface integrity SPRTIntroductionTurning process being considered by industry to finish machine hardened steel partsShould be competent with well-established grinding processChallenges in hard turning process:- Surface integrity (white layer)- Economical tool lifeStudies on surface integrity and tool wear important to make hard turning viable9/24/2004 Turning Hardened Steel Using Rotary Tool 4Hard Turning ChallengesWhite layer:- Featureless layer after etching- Different properties from bulk- Not desirable- Formed easily under aggressive conditions- Thermal phenomenon suspected- Need to reduce temperatureTool wear:- PCBN tool wear can be high- Need to improve tool lifeChallengesSituationConclusionsNext studiesTemperature modelSurface integrity SPRTIntroduction9/24/2004 Turning Hardened Steel Using Rotary Tool 5Rotary ToolsFeaturesProcessConclusionsNext studiesTemperature modelSurface integrity SPRTIntroductionVrVwVrVwSelf-propelled rotary tool process. 9/24/2004 Turning Hardened Steel Using Rotary Tool 6Features of Rotary ToolWith rotary tools, literature reports:- Lower cutting temperature- Lower forces- Lower tool wearEffect of this on hard turning?- Task 1: Surface integrity study- Task 2: Temperature and wear studiesFeaturesProcessConclusionsNext studiesTemperature modelSurface integrity SPRTIntroductionVrVw9/24/2004 Turning Hardened Steel Using Rotary Tool 7Task 1: Surface IntegrityConclusionsWhite layerSituationConclusionsNext studiesTemperature modelSurface integrity SPRTIntroductionPerform experiments to compare surface integrity under fixed and rotary tool conditionsRotarycartridgeV = 60 m/min,80 m/min, 100 m/minf = 0.2 mm/revDOC 0.1mmROTARYFIXEDFixed tool cartridge made similar to rotary unit• Workpiece: 52100 steel; ~58 HRc• Tool: micrograin carbide with proprietary nano-coating (Rotary Technologies Inc.)• Hardinge Precision Lathe T42SP• Thermal analysis to confirm observed trends9/24/2004 Turning Hardened Steel Using Rotary Tool 8 FIXED ROTARY  R1 Q (J) R1 Q (J) V100 0.36 188.4 0.53 6.7 V 80 0.34 141.1 0.50 11.8 V60 0.31 131.9 0.46 18.5  Task 1: Surface IntegrityConclusionsWhite layerSituationConclusionsNext studiesTemperature modelSurface integrity SPRTIntroduction(a)(b)(d)(c)(e)(f)V60V80V100Fixed Rotary(a)(f)Well established theories in orthogonal, oblique and rotary tool cutting usedQ: amount of heat transferred to workpieceR1: heat partition coefficient9/24/2004 Turning Hardened Steel Using Rotary Tool 9Surface Integrity SummaryConclusionsWhite layerSituationConclusionsNext studiesTemperature modelSurface integrity SPRTIntroductionWhite layer less likely to form under rotary tool cuttingLower tool wear seen in rotary cuttingWorn tools are known to produce white layerAnalytical calculations show less heat is going into workpieceA combination of thermal and lower wear could be the cause of the thin/absent white layer9/24/2004 Turning Hardened Steel Using Rotary Tool 10Task 2: Temperature ModelingDiscussionsResultsGeneralConclusionsNext studiesTemperature modelSurface integrity SPRTIntroductionThe analysis is based on data given by Shaw in a previous study when turning a steel tube with a drivenorthogonal rotary toolThe approach uses the finite element method (FEM). The required equation is derived from heat conduction theoryThe method involves modeling the rotating tool with a transport term added to the heat equationNumerical computation is performed with FEMLAB9/24/2004 Turning Hardened Steel Using Rotary Tool 11Temperature DistributionTemperature distributions in fixed and rotary toolsDiscussionsResultsGeneralConclusionsNext studiesTemperature modelSurface integrity SPRTIntroduction9/24/2004 Turning Hardened Steel Using Rotary Tool 12Temperature DistributionTemperature distributions in fixed and rotary toolsDiscussionsResultsGeneralConclusionsNext studiesTemperature modelSurface integrity SPRTIntroduction9/24/2004 Turning Hardened Steel Using Rotary Tool 13Cutting TemperatureDiscussionsResultsGeneralConclusionsNext studiesTemperature modelSurface integrity SPRTIntroduction400600800100012000 10 20 30 40 50 60 70 80 90i (deg)T (°K)Predicted Vw = 36.3 m/min  f = 0.14 mmShaw Vw = 27.4 m/min  f = 0.14 mmPredicted Vw = 13.5 m/min  f = 0.14 mmShaw Vw = 16.8 m/min  f = 0.05 mmShaw Vw = 4 m/min f = 0.05 mmShaw Vw = 70 m/min f = 0.05 mm9/24/2004 Turning Hardened Steel Using Rotary Tool 14DiscussionDiscussionsResultsGeneralConclusionsNext studiesTemperature modelSurface integrity SPRTIntroductionModel needs tool-chip interface geometry parametersThis model can also be used for a self-propelled rotary tool processResults given by the model show good agreement with measurements of ShawRotary tool temperatures are about 200°C lower than for an equivalent fixed toolResults thus far are promising for planned study of rotary tool wear9/24/2004 Turning Hardened Steel Using Rotary Tool 15Ongoing/Future WorkConclusionsNext studiesTemperature modelSurface integrity SPRTIntroductionFurther validate the temperature prediction modelCompare the temperature distributions for both fixed and rotary toolsCorrelate temperature and wear of fixed and rotary toolsTool life9/24/2004 Turning Hardened Steel Using Rotary Tool 16ConclusionsConclusionsNext studiesTemperature modelSurface integrity SPRTIntroductionImproved surface integrity with rotary toolThe lower temperature prediction is promising in terms of rotary tool wearThese two aspects should make rotary tool hard turning viable9/24/2004 Turning Hardened Steel Using Rotary Tool 17AcknowledgementCaterpillar Inc.Rotary Technologies Inc.Prof. Christophe Lescalier, ENSAM-Metz9/24/2004 Turning Hardened Steel Using Rotary Tool 18Thank you for your attention.Any questions or comments?9/24/2004 Turning Hardened Steel Using Rotary Tool 19Flank wear9/24/2004 Turning Hardened Steel Using Rotary Tool 20Flank wear

Turning Hardened Steel Using Rotary Tool

https://smartech.gatech.edu/bitstream/1853/13224/1/Presentation_Vincent_Dessoly.pdf

Turning Hardened Steel Using Rotary Tool

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