Surface integrity of die material in high speed hard machining, Part 2: Microhardness variations and residual stresses

Journal of Manufacturing Science and Engineering, Transactions of the ASME

Volumn 122, Issue 4, 2000, Pages 632-641

  El Wardany, T I ^a,b   Kishawy, H A ^a,c   Elbestawi, M A ^a  

^a MCMASTER UNIVERSITY   (Canada)

^b United Technology Research Cent   (United States)

^c UNIVERSITY OF NEW BRUNSWICK   (Canada)

Author keywords

[No Author keywords available]

Indexed keywords

EID: 0000756870     PISSN: 10871357     EISSN: 15288935     Source Type: Journal    
DOI: 10.1115/1.1286557     Document Type: Article

References (47)

1. 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, U.S.A.
2. Bailey, J. A., Jeelani, S., and Becker, S. E., 1976, “Surface Integrity in Machining AISI 4340 Steel,” Trans. ASME, J. Eng. Ind., 98, No. 3, pp. 999-1006.
3. Kono, Y., Hara, A., Yazu, S., Uchida, T., and Mori, Y., 1980, “Cutting Performance of Sintered CBN Tools,” Cutting Tool Materials, Proceedings of the International Conference, American Society for Metals, Ft. Mitchell, Kentucky, September 15-17, pp. 281-295.
4. 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, No. 3, pp. 169-175.
5. Schreiber, E., and Schlicht, H., 1986, “Residual Stresses After Turning of Hardened Components,” The International Conference on Residual Stresses, Garnish-Partenkirchen (FRG), pp. 853-860.
6. Ogata, M., 1989, “Einsatz von PCBN-Werkzeugen in der Produktion,” VDI Berichte, No. 762, pp. 271-279.
7. Wu, D. W., and Matsumoto, Y., 1990, “The Effect of Hardness on Residual Stresses in Orthogonal Machining of AISI 4340 Steel,” Trans. ASME, J. Eng. Ind., 112, No. 3, pp. 245-252.
8. König, W., Komanduri, R., Tönshoff, H. K., and Ackershott, G., 1990, “Machining of Hard Materials,” Ann. CIRP, 39, No. 1, pp. 417-427.
9. König, W., Berktold, A., and Koch, K. F., 1993, “Turning Versus Grinding-A Comparison of Surface Integrity Aspects and Attainable Accuracies,” Ann. CIRP, 42, No. 1, pp. 39-43.
10. 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.
11. Tönshoff, H. K., Wobker, H. G., and Brandt, D., 1995, “Tribological Aspects of Hard Turning with Ceramic Tools,” J. Soc. Tribol. Lubr. Eng., 51, No. 2, pp. 163-168.
12. Tönshoff, H. K., Wobker, H. G., and Brandt, D., 1995, “Hard Turning-Influences on the Workpiece Properties,” Trans. NAMRI/SME, 23, pp. 215-220.
13. Abráo, A. M., and Aspinwall, D. K., 1996, “The Surface Integrity of Turned and Ground Hardned Bearing Steel,” Wear 196, pp. 279-284.
14. Liu, C. R., and Barash, M. M., 1982, “Variables Governing Patterns of Mechanical Residual Stress in a Machined Surface,” Trans. ASME, J. Eng. Ind., 104, No. 3, pp. 257-264.
15. 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-Vol. 8, pp. 269-276.
16. Okushima, K., and Kakino, Y., 1971, “The Residual Stress Produced by Metal Cutting,” Ann. CIRP, 10, No. 1, pp. 13-14.
17. El-Khabeery, M. M., and Fattouh, M., 1989, “Residual Stress Distribution Caused by Milling,” Int. J. Mach. Tools Manuf., 29, No. 3, pp. 391-401.
18. Yang, G., Tite, C. N. J., Smith, G. T., Hope, A. D., and Noroozi, S., 1995, “Determination of Residual Stresses Induced by hardened Steel Turning Using Finite Element Methods,” DE-Vol. 83, 1995 Design Engineering Technical Conferences, Vol. 2, ASME 1995, pp. 205-211.
19. Palmer, W. B., and Oxley, P. L. B., 1959, “Mechanics of Orthogonal Machining,” Proc. Inst. Mech. Eng., 173, No. 24, pp. 623-638.
20. Lee, E. H., and Shaffer, B. W., 1951, “The Theory of Plasticity Applied to a Problem of Machining,” Trans. ASME, J. Appl. Mech., 73, pp. 404-413.
21. Shaw, M. C., 1984, Metal Cutting Principles, Oxford Science, New York.
22. Barash, M. M., and Schoech, W. J., 1970, “A Semi-Analytical Model of the Residual Stress Zone in Orthogonal Machining,” Proc. 11th International M.T.D.R. Conf., London, Pergamon Press.
23. Lajczok, M. R., 1980, “A Study of Some Aspects of Metal Machining Using the Finite Element Method,” Ph.D. dissertation, North Carolina State University.
24. Natarajan, R., and Jeelani, S., 1983, “Residual Stresses in Machining Using Finite Element Method,” Comput. Eng. Comput. Software Appl., 3, ASME, New York, pp. 19-20.
25. Wang, B. P., Sadat, A. B., and Twu, M. J., 1988, “Finite Element Simulation of Orthogonal Cutting-A Survey,” in Kiefer, B. V., et al., eds, Materials in Manufacturing Processes, ASME Winter Annual Meeting, Chicago, IL, November 27-December 2.
26. Liu, C. R., and Lin, Z. C., 1985, “Effects of Shear Plane Boundary Condition on Stress Loading in Orthogonal Machining,” Int. J. Mech. Sci., 27, No. 5, pp. 281-290.
27. Mishra, A., and Prasad, T., 1985, “Residual Stresses Due to A Moving Heat Source,” Int. J. Mech. Sci., 27, No. 9, pp. 571-581.
28. Lin, Z. C., Lin, Y. Y., and Liu, C. R., 1991, “Effect of Thermal Load and Mechanical Load on the Residual Stress of a Machined Workpiece,” Int. J. Mech. Sci., 33, No. 4, pp. 263-278.
29. Shih, A. J., and Yang, H. T. Y., 1993, “Experimental and Finite Element Predictions of Residual Stresses due to Orthogonal Metal Cutting,” Int. J. Numer. Methods Eng., 36, pp. 1487-1507.
30. Shih, A. J., 1995, “Finite Element Simulation of Orthogonal Metal Cutting,” Trans. ASME, J. Eng. Ind., 117, No. 1, pp. 84-91.
31. Subhas, B. K., Bhat, R., Balakrishna, H. K., and Ramachandra, 1998, “Dimensional Instability Studies in Machining of Inconel 718 Nickel Based Superalloys as Applied to Aerogas Turbine Components,” Int. Gas Turbine & Aeroengine Congress & Exhibition, Stockholm, Sweden, June 2-5, 1998.
32. Turbat, A, Convert, F., and Skalli, N., 1983, Prediction of Thermal Residual Stresses by the Finite Element method-Effect of a Phase Change, Numerical Methods in Thermal Problems, Proceedings of the Third International Conference, pp. 292-301.
33. Jeelani, S., and Bailey, J. A., 1986, “Residual Stress Distribution in Machining Annealed 18 percent Nickel Maraging Steel,” J. Eng. Mater. Technol., 108, pp. 93-98.
34. Flower, E. C., MacEwan, S. R., and Holden, J. H., 1987, “FEA Predictions of Residual Stress in Stainless Steel Compared to Neutron and x-ray Diffraction Measurements,” The 2nd International Conference on Advances in Numerical Methods in Engineering: Theory and Application, Swansea, Walels, U.K., July 6-10, 1987.
35. Wiesner, C., 1992, “Residual Stresses After Orthogonal Machining of AISI 304: Numerical Calculation of the Thermal Component and Comparison with Experimental Results,” Metall. Trans. A, 23, pp. 989-996.
36. Hsu, H. C., 1992, “An Elasto-Viscoplastic Finite Element Model of Orthogonal Metal Cutting for Residual Stress Prediction,” Ph.D. thesis, North Carolina State University, 1992.
37. Shirakashi, T., Obikawa, T., Sasahara, H., and Wada, T., 1993, “Analytical Prediction of the Characteristics Within Machined Surface Layer (1st Report) The Analysis of the Residual Stress Distribution Within Machined Surface layer with FEM Simulation,” Seimitsu Kogaku, Kaish/J. Jpn. Soc. Precis. Eng., 59, No. 10, pp. 1695-1700.
38. Shirakashi, T., Shsahara, H., Obikawa, T., and Wada, T., 1994, “The Analytical Prediction of Residual Stress Within Machined Sublayer and Its Effect on Accuracy,” Int. J. Jpn. Soc. Precis. Eng., 28, No. 3, pp. 200-205.
39. Sasahara, H., Obikawa, T., and Shirakashi, T., 1996, “FEM Analysis of Cutting Sequence Effect on Mechanical Characteristics in Machined Layer,” J. Mater. Process. Technol., 62, pp. 448-453.
40. Zhang, B., and Bagchi, A., 1994, “Finite Element Simulation of Chip Formation and Comparison with Machining Experiment,” Trans. ASME, J. Eng. Ind., 116, No. 3, pp. 289-297.
41. Shih, A. J., 1993, “Finite Element Analysis of the Rake Angle Effects in Orthogonal Metal Cutting,” PED-Vol. 64, Manufacturing Science and Engineering, ASME Winter Annual Meeting, pp. 475-483.
42. Obikawa, T., and Usui, E., 1996, “Computational Machining of Titanium Alloy-Finite Element Modeling and a Few Results,” Trans. ASME, J. Eng. Ind., 118, No. 2, pp. 208-215.
43. Maekawa, K., Nakano, Y., and Kitagawa, T., 1996, “Finite Element Analysis of Thermal Behavior in Metal Machining, 1st Report, Influence of Thermophysical Properties on Cutting Temperature,” Trans. Jpn. Soc. Mech. Eng., 62, No. 596, C, pp. 857-863.
44. Trent, E. M., 1991, Metal Cutting, 3rd ed., Butterworth-Heinemann.
45. Tlusty, J., and Masood, Z., 1978, “Chipping and Breakage of Carbide Tools,” Trans. ASME, J. Eng. Ind., 100, No. 4, pp. 403-412.
46. Elbestawi, M. A., Srivastava, A. K., and El-Wardany, T., 1996, “A Model for Chip Formation During Machining of Hardened Steel,” Ann. CIRP, 45, No. 1, pp. 71-76.
47. Mills, A. F., 1992, Heat Transfer, Irwin, Boston, pp. 330-331.