G.d.S. Galoppi et al.

/ Journal of Materials Processing Technology 179 (2006) 146–153

151Fig. 6. Cutting edge profile after test condition.
4.5. Surface profiler Hommelwerke T8000
P r o fi l e r t r a c e r s a r e e q u i p m e n t s e m p l o y e d i n o r d e r t o m e a s u r e the surface roughness
(see Fig. 3). Its operation occurs troughthe sliding of a diamond point on the workpiece
surface, asillustrated on Fig. 4. Among others the measured roughness by
Fig. 7. Cutting edge breakage (a)
V
c
=183m/min,
f
=0.15mm/rev; (b)
V
c
=183m/min,
f
=0.08mm/rev; (c)
V
c
=137m/min,
f
=0.11mm/rev; (d)
V
c
=91m/min,
f
=0.15mm/rev.
such equipments can be expressed by:
R
a
=
1
L

L
0
|
y
x
−
y
med
|
d
x
(1)
R
q
=
1
L

L
0
(
|
y
x
−
y
med
|
)
2
d
x
(2)
Fig. 8. Experimental measurements and Taylor equation predicted results for the tool life of CBN
inserts with differents hard surface coatings manufactured by twosuppliers (1 and 2). Workpiece
dimensions: 25mm
×
250mm (a) TiN surface coatings produced by supplier 1, (b) no coated surface produced by
supplier 1, (c)TiAlN surface coatings produced by supplier 2, (d) no coated surface produced by
supplier 2.
152
G.d.S. Galoppi et al. / Journal of Materials Processing Technology 179 (2006) 146–153
R
t
=
y
max
−
y
min
(3)Atexpressionsabove,
y
ave
m e a n s t h e a v e r a g e v a l u e a t v e r t i c a l direction,
y
(
x
)
−
y
ave
is the deviation ath center line average forany position (
x
) during the measuring length (
x
= 0 a t
x
=
L
).
R
a
represents average roughness,
R
q
t h e r o o t m e a n s s q u a r e roughness and
R
t
is the greatest amplitude of the roughness(“peak-to-valley”). In order to measure
the roughness of theturned parts it was employed a surface profiler HommelwerkeT8000,
which presents an resolution of
±
8

m/1nm. Due to itscharacteristics this equipment was also used to trace the profileof surfaces
of the several CBN inserts.
5. Experimental results for the tool life and wear
5.1. Cratering wear
Fig. 5 shows images obtained by optical microscopy at dif-ferent tool wear stages. These
images represent at lower par oneinsert at an early stage of low wear, just after the
machiningbeginning. At image at middle it is shown an intermediary wearstage, just before the
end of the tool life. The tools representedat Fig. 5 were submitted to same cutting
conditions, i.e., cut-ting speed of 91m/min and feed rate of 0.152mm/rev, whichwas
the condition that presented better tool life. Due to the diffi-culty in obtaining good images into
a same time interval, all therepresented images are regarding different machining intervals.The
first image at Fig. 5 shows the evolution of the crateringwear that occurs on the insert with lower
content of CBN.
Thist y p e o f w e a r i s t y p i c a l a n d i s m o r e a c c e n t u a t e d a t t o o l n o t c o a t e d . A t t h
eupperpartoftheimageitbecomessharpthatthecrateringbeginstobef
o r m e d a t t h e r e g i o n w h e r e t h e r e i s c o n t a c t b e t w e e n toolandworkpiece.Thi
s r e g i o n i s d e fi n e d b y t h e d e p t h o f c u t t i n g and the feed rate, regarding that this cratering
occurred at the T-bevelled region.The images sequences of Fig. 5 show the growing
evolutionof the cratering. However, difficult to identify it at the images
of F i g . 5 ,ac u t t i n g e d g e t h a t w a s s t r o n g l y n e g a t i v e a n d r o b u s t d u e t o t h e T -
bevelling(chamfer),becomesbrittleandturnstoapositive r a k e a n g l e a s r e s u l t
f r o m t h e c r a t e r i n g ( s e e F i g . 6 as a r e f e r e n c e ) . As seen at the images of Figs. 5 and 6,
the cratering arised atthe inserts with and without coating becomes very similar afterthe
moment when the coating is weared by the friction contact.It worth to note a difference at
initial wear mechanism forcoated tool, as it instead of suffer cratering since the beginningof
the machining process, at a first stage presents a cracking of the coatings. As an advantage for
the coated insert it can be saidthat coating layers act as an delayer element for the
cratering,as it only begins after a complete remotion of coating by wear.Thus improving in
such way the coated tool life.
5.2. Tool breakage
T h e i m a g e s o b t a i n e d b y t h e o p t i c a l m i c r o s c o p y d o n o t a l l o w s for a detailed
observation of the cutting edge changings. In this
Fig. 9. Measured tool life as function of feed rate and cutting speed—CBN inserts produced by
suppliers 1 and 2 with and without coatings.
G.d.S. Galoppi et al. / Journal of Materials Processing Technology 179 (2006) 146–153
153
sense, the profile of cutting edge was traced using a profilerHommelwerke. The
surface profile presented at F i g . 6 statesclear that the cutting edge, that initially
was strong negativedue to the T-chamfer, becomes positive due to the cratering
thatl e a d s t o a c u t t i n g e d g e g e o m e t r y c h a n g i n g . A t y p i c a l t o o l r u p t u r e can be seen
at Fig. 7. All tools usually trend to present similarcharacteristics when broken, as the fracture
typically occurs atcutting edge area enbrittled by cratering wear.
5.3. Tool life
Regardingthatusuallythetoolsbreakdueafractureorcracks a t t h e c u t t i n g e d
g e , i t w a s n o t d e fi n e d a c r a t e r i n g s i z e a s a p a r a m - eter for the evaluation of end of
the tool life. Table 3 presentedearly contains the experimental results for each one of the
testconditions. Results show that the cutting speed influences thetool life more
significantly than the feed rate. Thus, a lowerspeed results into a significant increase at
total cutting time aswell as at the material removal volume, improving in this sensethe tool life. A
decreasing at the feed rate leads too an increas-ing at tool life, however not in such a so
significant way (seeFig. 8a–
d).F u r t h e r m o r e , a n a l y s i n g t h e t o o l l i f e a s a f u n c t i o n o f t h e m a t e - rial removal
volume, it is observed that a decreasing at the feedr a t e d i s c o u n t e n a n c e t h e t o o l l i f e .
I n o r d e r t o p r o c e e d a c o r - rect selection of the best machining conditions to be
appliedit becomes necessary that the parameter evolved with the toollife has be
understood, namely, the material removal volume,material removal rate, tool cost and
operational costs. In thecase of the CBN tools an economical analysis becomes
indis-pensable for the optimization of the hard turning operations assuch a type of tool is
extremely expensive. This optimizationcan be performed by the use of the Taylor equation.
As shownin Table 3, the Taylor equation (Eq. (4)) presents a good corre-lationship with the
experimental data, stating clear that for thestudy of the case treated at this paper it can be
employed for thedetermination of the initial parameters (see Fig. 9a–d).
T
=
kv
a
f
b
(4)
6. Conclusions
T h e C B N i n s e r t s c o a t e d w i t h T i N , T i A l N c o a t i n g a n d a w i p e r geometrytestedun
derconditionsrangingoverthecompletefieldof application recommended by tool ma
nufacturers presentssome peculiarities showed at the results early discussed.
Theinserts were monitored during their tool life allowing for theobservation of cracking
flank surface and cratering on the rakesurface.B o t h f o r t h e T i N c o a t e d a s w e l l a s f o r
t h e T i A l N c o a t e d inserts, they presented a significantly cracking on the
coatingsurface layer. Resulting at the removal of the surface hard coat-ing by cracking, the
cratering that arises on insert surfaces issimilar to that found on the no coated
inserts.T h e i n s e r t s w i t h a w i p e r g e o m e t r y p r e s e n t e d a b e h a v i o u r v e r y similar to the
no coated ones coming from the same supplier,unless their tool life. Those were
lower on the inserts with thewiper geometry when compared with the others.The
optimized selection of the cutting parameters shall becarried out balancing the
tool life versus the productivity. Ingeneral terms, cutting conditions that improve the
productivityl e a d s t o a d e c r e a s i n g o n t h e t o o l l i f e . A i m i n g t o b e t t e r u n d e r s t a n d t h e e f
f e c t s o f t h e c u t t i n g c o n d i t i o n s u n d e r t h e t o o l l i f e , a n e m p i r i - cal Taylor equation was
employed. The empirical constants “
a
”a n d “
b
” from this equation was obtained from the literature.As the tool life estimated by
the Taylor equation resulted in amaximal deviation of 12.84min,
regarding the experimentallydetermined tool life, it can be stated that it presented a good
cor-relationship. The experimental results from this work are part of a bigger investigation carried
out in order to study the effects of the cutting parameters on the wear of the CBN
tools.A s a l r e a d y m e n t i o n e d a t t h e o p t i m i z e d s e l e c t i o n o f t h e machining
parameters a balancing between the tool life ver-sus the productivity shall be
done, it should be also regardedthe effects of the material removal rate on the machined
surfacequality desired to be obtained. Future works shall be carried outaiming to correlate
and understood the above-mentioned effectsand their interrelationships.
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