Accepted Manuscript .pdf (1.81 MB)
Download file

Enhanced wear performance of laser machined tools in dry turning of hardened steels

Download (1.81 MB)
journal contribution
posted on 22.04.2020, 12:48 by Manuela PacellaManuela Pacella, Daniel Brigginshaw
Polycrystalline boron nitride cutting tools are currently used for precision machining of automotive components made of hardened steel due to their high wear resistance and long durability, however adhesion of workpiece to the cutting tool can reduce cutting tool lifetime. Laser surface engineering of polycrystalline boron nitride single point cutting tools using a nanosecond fibre laser is proposed to improve their wear properties and extend tool life in turning of continuous hardened steel components. The effect of different designs on the wear properties was investigated in turning tests under dry conditions and compared to benchmark cutting tools made of the same material. Condition monitoring of machining forces revealed a 20% reduction of cutting force and 30% reduction of feed force for tools with crosshatch design and grooves perpendicular to chip flow direction, when benchmarked to commercial cutting tools. The number of grooves in contact with the forming chip contributed to the creation of three distinguished interfacial secondary deformation areas. Texturing the chamfer proved to alter the dynamic of chip formation in the secondary deformation zone, while engineering the formation of laser-induced solid lubricant h-BN improved the heat dissipation rate in the secondary and tertiary deformation areas. To the best of authors’ knowledge, this paper reports for the first time the possibility of simultaneously engineer geometry and chemistry of PcBN cutting tools so to enhance their service life by up to 20%.

History

School

  • Mechanical, Electrical and Manufacturing Engineering

Published in

Journal of Manufacturing Processes

Volume

56

Issue

Part A

Pages

189 - 196

Publisher

Elsevier

Version

AM (Accepted Manuscript)

Rights holder

© The Society of Manufacturing Engineers

Publisher statement

This paper was accepted for publication in the journal Journal of Manufacturing Processes and the definitive published version is available at https://doi.org/10.1016/j.jmapro.2020.04.058.

Acceptance date

16/04/2020

Publication date

2020-05-12

Copyright date

2020

ISSN

1526-6125

Language

en

Depositor

Dr Manuela Pacella. Deposit date: 20 April 2020