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Machining hardened steel with polycrystalline cubic boron nitride cutting tools
Bibliografi
Author:
Kurfess, Thomas R.
(Advisor);
Dawson, Ty Grant
Topik:
Mechanical engineering
Bahasa:
(EN )
ISBN:
0493771824
Penerbit:
Georgia Institute of Technology
Tahun Terbit:
2002
Jenis:
Theses - Dissertation
Fulltext:
3061412.pdf
(0.0B;
5 download
)
Abstract
Machining hardened steels has become an important manufacturing process, particularly in the automotive and bearing industries. Abrasive processes such as grinding have typically been required to machine hardened steels, but advances in machine tools and cutting materials have allowed hard turning on modern lathes to become a realistic replacement for many grinding applications. There are many advantages of hard turning, such as increased flexibility, decreased cycle times, reductions in machine tool costs, and elimination of environmentally hazardous cutting fluids. Despite these advantages, implementation of hard turning remains relatively low, primarily due to concerns about the quality of hard turned surfaces and a lack of understanding about the wear behavior of polycrystalline cubic boron nitride (PCBN) cutting tools. Because PCBN tools are expensive, excessive tool wear can eliminate the economic advantage of hard turning. To address this concern, this research investigated the effects of changing process conditions on wear behavior when turning hardened AISI 52100 steel (62 HRC) with both ceramic-coated and uncoated PCBN cutting tools. Traditional techniques of characterizing tool condition (optical and scanning electron microscopy) provide important information about tool wear, but are generally restricted to qualitative analysis. For a quantitative study of wear, a white light interferometer was used to obtain three-dimensional images of the wear scar on cutting tools. Data from these measurements allow quantification of flank wear, crater wear, and tool life, and models were developed that describe the behavior well. Using three-dimensional wear data, a new technique was developed to determine the volumetric wear loss in the crater and flank regions by localizing the interferometer data to a model of the tool, then integrating deviations between the localized data and the model. This allows a quantitative comparison of the two wear modes, which cause changes in cutting forces and surface quality over the lives of tools.
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