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j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 2 0 9 ( 2 0 0 9 ) 10921104

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Hard machining of hardened bearing steel using cubic boron nitride tool
Mohamed Athmane Yallese a , Kamel Chaoui b, , Nassereddine Zeghib b , Lakhdar Boulanouar b , Jean-Francois Rigal c
Laboratoire de M canique et des Structures (LMS), 8 May 1945 University, P.O. Box 401, Guelma 24000, Algeria e Laboratoire de Recherche M canique des Mat riaux et Maintenance Industrielle (LR3MI), Badji Mokhtar University, e e P.O. Box 12, Annaba 23000, Algeria c Laboratoire de M canique des Contacts et des Solides (LaMCoS) INSA of Lyon, 20 Albert Einstein Avenue, e 69621 Villeurbanne Cedex, France
b a

a r t i c l e
Article history:

i n f o

a b s t r a c t
In many cases, hard machining remains an economic alternative for bearing parts fabrication using hardened steels. The aim of this experimental investigation is to establish the behaviour of a CBN tool during hard turning of 100Cr6-tempered steel. Initially, a series of long-duration wear tests is planned to elucidate the cutting speed effects on the various tool wear forms. Then, a second set of experiments is devoted to the study of surface roughness, cutting forces and temperature changes in both the chip and the workpiece. The results show that CBN tool offers a good wear resistance despite the aggressiveness of the

Received 11 July 2007 Received in revised form 7 March 2008 Accepted 15 March 2008

Keywords: Hard turning Hardened steel Cubic boron nitride Wear Roughness Cutting forces

100Cr6 at 60HRC. The major part of the heat generated during machining is mainly dissipated through the chip. Beyond 280 m/min, the machining system becomes unstable and produces signicant sparks and vibrations after only a few minutes of work. The optimal productivity of machined chip was recorded at a speed of 120 m/min for an acceptable tool ank wear below 0.4 mm. Beyond this limiting speed, roughness (Ra ) is stabilized because of a reduction in the cutting forces at high speeds leading to a stability of the machining system. The controlling parameter over roughness, in such hard turning cases, remains tool advance although ideal models do not describe this effect rationally. Surface quality obtained with CBN tool signicantly compared with that of grinding despite an increase in the advance by a factor of 2.5. A relationship between ank wear (VB) and roughness (Ra ) is deduced from parametric analysis based on extensive experimental data. 2008 Elsevier B.V. All rights reserved.

1.

Introduction

During the process of material cutting, complex and mutual interactions are created between tool and workpiece at the contact surface. Consequently, in this system, signicant forces and high temperatures are recorded causing wear and sometimes breakage of the tool. Usually, such conditions lead

to the damage of both contact surfaces and reduce the precision on the geometrical shapes or modify the mechanical characteristics. It is well known that wear process of cutting tools is a very complicated phenomenon as contact surfaces of the system are subjected to physical and chemical changes which contribute to the progressive destruction of the active part surface layers. Moreover, wear also affects geometrical

Corresponding author. Tel.: +213 38 87 11 09; fax: +213 38 87 11 09. E-mail address: chaoui@univ-annaba.org (K. Chaoui). 0924-0136/$ see front matter 2008 Elsevier B.V. All rights reserved. doi:10.1016/j.jmatprotec.2008.03.014

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Nomenclature Nomenclature ap depth of cut (mm) constants C1 , C2 CBN cubic boron nitride e, exp exponential operator f feed rate (mm/rev) Fa axial force (N) Fr radial force (N) Fv tangential force (N) HB Brinell hardness HRC Rockwell hardness K, tting constants for roughness model KT crater wear (mm) [KT] allowable crater wear (mm) R2 determination coefcient Ra Arithmetic mean roughness ( m) theoretical average roughness ( m) Ra th Rt total roughness ( m) Rt th theoretical total roughness ( m) mean depth of roughness ( m) Rz r, R nozzle radius (mm) T tool life (min) t cutting time (min) t cutting temperature ( C) VB ank wear (mm) [VB] allowable ank wear (mm) Vc cutting speed (m/min) x1 , x2 , x3 , constants describing cutting forces y1 , y2 , y3 , y4 constants describing roughness Greek symbols c clearance angle ( ) cutting edge angle ( ) r rake angle ( ) cutting edge inclination angle ( )

parameters of the tool, generated heat quantity, cutting pressures and induced compressive surface residual stresses, tool lifetime and the micro-geometrical precision of the machined surface. Current technical progress helped to develop the use of very hard materials associated with difcult machinability in several industrial domains of equipment and spare parts manufacture. Although the behaviour of the conventional cutting tools is limited to particular conditions, high-speed steels, carbides and cermets tools remain largely used for turning the majority of materials. Whenever hardness is increased, such as in the case of quenched steels or hardened cast irons as well as nickel-based refractory alloys and some metallic composite materials, it becomes necessary to use appropriate cutting tools, which respond to these new requirements. Therefore, materials having a signicant abrasion resistance as well as a raised hardness, need to be machined with super-hard tools like cubic boron nitrides with polycrystalline structure (PCBN). Huang et al. (2006) presented a thorough review which discusses CBN material tool microstructure, wear patterns

involved and CBN tool wear rate modelling under hard turning. They also concluded that assessments of the cutting tool condition based on tool geometry, cutting regimes and the nature of wear in terms of VB and KT need better understanding. Chou et al. (2002) experimentally investigated the performance and wear behaviour of different CBN tools in nish turning of hardened AISI 52100 steel (DIN 100Cr6). In this study, it was established that low CBN content materials provide the best performance in hard turning in terms of tool life and surface nish. In the machining of hard light titanium alloys, Nabahani (2001) found that PCBN tools showed reduced tool ank wear and delivered a good surface quality compared to the various carbide tools. The failure of these tools is the result of plastic deformations under combined signicant mechanical and thermal stresses in the vicinity of the cutting edge and the low-wear rate of the PCBN is primarily attributed to a reduced chemical reactivity in contact of titanium alloys. Arunachalam et al. (2004) studied both residual stress and surface nish generated during facing of Inconel 718 steel using CBN and mixed ceramic cutting tools as a function of speed, depth of cut, coolant and tool geometry. It is found that mixed ceramic cutting tools induce tensile residual stresses with a much higher magnitude than CBN tools. The residual stresses and the surface roughness obtained when using CBN cutting tools are more sensitive to cutting speeds than depth of cut. The use of coolant resulted in either compressive residual stresses or lowered the magnitude of the tensile residual stresses, whereas dry cutting always was associated with tensile residual stresses. Thiele et al. (1999) presented results of an experimental study on the effect of cutting edge geometry and workpiece hardness on residual stresses in nish hard turning of 100Cr6 steel. They concluded that both factors are signicant for surface integrity of nish hard turned components. Today, it is established that the wear resistance of the CBN is improved mainly because of the much reduced solubility of boron. Whenever the mechanisms of dissolutiondiffusion prevail, the performance of CBN tools becomes more interesting than that of coated carbides and mixed ceramics as shown by Yallese et al. (2005). Alternatively, Banga and Abrao (2003) found that cutting speed is the factor which most effects tool life when turning hardened 100Cr6 and PCBN cutting tools provide longer tool life than mixed and composite ceramics. The superiority of CBN tools for hard materials machining was illustrated in the study performed by Lima et al. (2005) on the turning of AISI 4340 (48 HRC) steel using PCBN and coated carbides tools. Previously, Luo et al. (1999) studied the wear behaviour in hard turning of the same alloy steel by CBN and ceramic tools and they found that the ank wear was reduced as work material hardness increased up a critical value of 50 HRC. In addition, wear mechanisms by diffusion, abrasion and adhesion were discussed by Poulachon et al. (2003) and usually it is concluded that these mechanisms are prevalent during wear process of CBN tools. The major inuencing factor on the tool wear is the presence of various carbides in the steel microstructure. The hardness of these carbides varies significantly, causing different wear rates when turning 100Cr6, X155CrMoV5, X38CrMoV5 and 35NiCrMo16 steels. In these cases, the ank wear on the tool has resulted in grooves caused by the major abrasive action of carbides. Chou (2003) stated

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Table 1 Chemical composition of 100Cr6 steel %C


1.05

% Mn
0.38

% Si
0.21

%P
0.03

%S
0.028

% Cr
1.41

% Ni
0.21

that high CBN content tools with metallic binder are recommended for roughing, but low CBN content tools with ceramic binder are more appropriate for nishing. Finally, Lahiff et al. (2007) concluded that different theories exist regarding involved tool wear mechanisms; however, there is a general agreement among researchers that PCBN tool wear is complex and no single mechanism alone provides a satisfactorily explanation. It is also agreed that abrasion makes a signicant contribution to ank wear (VB) that is caused by hard carbide particles and martensite in workpiece and also by CBN grains issued from the cutting tool. The aim of this investigation, which comprises of two parts, is to establish the machining conditions under hard turning of 100Cr6 steel using a cubic boron nitride tool. In the rst part, tool wear evolution is observed by optical microscopy in order to identify the various wear patterns as a function of various cutting speeds, whereas in the second part, a roughness study is conducted on the machined part according the cutting regime parameters. The experimental results are used to draw relationships which govern ank wear, roughness criterion and cutting forces under hard turning.

2.

Experimental procedure

Experiments devoted to wear analysis were carried out in accordance with long-duration wear tests as stated by standard ISO 3685 in order to evaluate the lifetime of CBN tools at different cutting speeds. Alternatively, roughness and cutting forces tests were realized according to experiment planning using both unifactorial and multifactorial methods. Machining was performed on 100Cr6 (AISI 52100) steel rods. Specimen diameter and length were, respectively, 80 and 400 mm, respectively, whereas for roughness experiment only half of the length was considered. Because of its high wear resistance, 100Cr6 steel is especially recommended for the manufacture of various dies, proling rollers, balls and bearing cages. It is also employed in cold working of forming matrices, of proling cylinders and for wear coating purposes. Its chemical composition is given in Table 1. The steel hardness is increased from 285 HB to 60 HRC (the Vickers hardness from 260 to 710 daN/mm2 ) using a quenching treatment at 850 C followed by tempering at 220 C as suggested by the suppliers recommendations. A 6.6 kW Tos Trencin lathe type SN40 was used for the turning operations. Cutting inserts are removable and offered eight squared working edges. The chosen CBN tool is commercially known as CBN7020 and it is essentially made

of 57% CBN and 35% Ti(C,N). Its ISO designation is SNGA12 04 08 S01020 CB7020 and was manufactured by Sandvik. The physical properties of the CBN7020 tool are summarized in Table 2. Tool holders are codied as PSBNR2525K12 with a common active part tool geometry described by r = +75 ; c = +6 ; = 6 and = 6 . Wear follow-up was achieved using an optical Hund (W-AD) microscope equipped with a digital display and a colour charge-coupled device camera, enabling a precision of 0.001 mm to be obtained. The cutting forces in X, Y and Z directions were recorded using a standard quartz dynamometer (Kistler 9257B) allowing measurements from 5 to 5 kN. Instantaneous roughness criteria measurements (Ra , Rt , and Rz ) for each cutting condition were obtained from a Surftest 301 Mitutoyo roughness meter coupled with a prole printer. It consists of a diamond point (probe) with a 5 m radius and moves linearly on the working surface. The length examined is 4.0 mm with a basic span of 0.8 mm. The measured values of Ra are within the range 0.05 to 40 m while for Rt and Rz , they lay between 0.3 and 160 m. Roughness measurements were directly obtained on the same lathe without disassembling the turned part in order to reduce uncertainties due to resumption operations. The measurements were repeated 3 times out of 3 generatrices equally positioned at 120 and the result is an average of these values for a given machining pass. Error magnitude is globally estimated around 10% for the obtained data and between 15 and 20% for very low roughness values which are in agreement with the instrument characteristics and the experimental conditions. A Rayner 3I infrared pyrometer was used to determine the temperatures of the chip, part, and cutting tool from a remote data acquisition system. This pyrometer is designed to measure temperatures within the range from 30 to 1200 C and covers emissivities range from 0.10 to 1.00. The cutting conditions adopted for the wear and roughness experiments are illustrated in Table 3. The wear tests were carried out without lubrication at a feed rate (f) of 0.08 mm/tr, a depth of cut (ap ) of 0.5 mm and a varying cutting speed (Vc ) from 90 to 350 m/min. On the other hand, the following intervals were selected for both roughness and cutting forces experiments: 0.08 < f < 0.24 mm/tr; 0.1 < ap < 1.0 mm and 60 < Vc < 350 m/min. The wear behaviour of the CBN was assessed on the basis of allowable ank wear limits of [VB] = 0.30 mm and [KT] = 0.15 mm. Some wear and roughness values are obtained beyond these limits in order to observe the complete behaviour of the tool under extreme conditions.

3.

Results and discussion

The various combinations of the cutting regime parameters (Vc , f and ap ) are used for specic correlations as shown in Table 3. Such correlations have already been tested for roughness measurements and the simulated predictions were

Table 2 Physical properties of CBN Material


CBN

Hardness HV (daN/mm2 )
2800

Tenacity (MPa m1/2 )


4.2

Youngs modulus (GPa)


570

Density (g/cm3 )
4.3

Grain size ( m)
2.5

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Table 3 Roughness and cutting force as a function of the experimental plan Parameters Codied values Test
1 2 3 4 5 6 7 8

Criteria/values Actual values X3


1 1 1 1 +1 +1 +1 +1

Roughness Vc (m/min)
90 90 90 90 180 180 180 180

Cutting force Rt ( m)
1.9 5.2 2.1 5.8 1.4 4.8 1.5 5.2

X1
1 +1 1 +1 1 +1 1 +1

X2
1 1 +1 +1 1 1 +1 +1

f (mm/rev)
0.08 0.2 0.08 0.2 0.08 0.2 0.08 0.2

ap (mm)
0.2 0.2 0.6 0.6 0.2 0.2 0.6 0.6

Ra ( m)
0.23 1.08 0.27 1.05 0.18 0.88 0.21 0.90

Rz ( m)
1.4 4.9 1.6 5.2 1.1 4.1 1.3 4.5

Fr (N)
132.2 166.5 216.3 302.1 111.5 144.5 206.4 280.6

Fa (N)
71.1 87 222.3 274 66.1 83.1 202.2 247.7

Fv (N)
106.3 157 230.5 385 90.5 126.4 215.4 356.4

satisfactory. In this case, an extension of the model is made to describe the cutting forces data using a similar procedure. In other words, these correlations concern the cutting force (F) represented by (Fr , Fa and Fv ) and the roughness (R) represented by (Ra , Rt and Rz ) in the general following forms which are used in the work of Yallese (2005):
x F = C1 f x1 ax2 Vc 3 p y R = C2 f y1 ay2 Vc 3 p

(1) (2)

where C1 , C2 , x1 , x2 , x3 , y1 , y2 and y3 are constants experimentally assessed. Depending on the sign and the value of each exponent (xi or yi ), the importance of each cutting parameter is deduced which helps understanding the basic effect that underlines the optimum machining conditions.

3.1.

Tool wear

Fig. 1ad shows the morphology of ank (VB) and crater (KT) wears as a function of time for a cutting speed of 90 m/min. Initially, ank wear develops according to a regular band which widens with cutting time and becomes irregular beyond 50 min. Wear according to the surface attack begins in the form of a small crater which extends until it reaches the preceding ank wear. At this time and in the vicinity of the

cutting edge, a signicant wear in the form of cavity appears as shown in Fig. 2 at 120 m/min. This state of damage weakens the tool nozzle leading progressively to its nal collapse and this observation is common and foreseeable for CBN tools for subsequent speeds. At a much higher speed of 280 m/min, the degradation of the CBN insert according to its both contact surfaces becomes intense and catastrophic as shown in Fig. 3 and tool nozzle deterioration is denitely visible after only 7 min of machining (Fig. 3b). At 15.5 min chipping took place in both wear directions and extended in the diagonal part of the insert forming a rather deep crucible at the nozzle tool (Fig. 3d). On the nozzle contour, the fracture process deteriorated the chamfer reinforcement of the cutting edge, whereas on the opposite side, it reached the limit of the CBN insert. Under extreme conditions of cutting speed, i.e. at 350 m/min, the effect on wear morphology of is more pronounced as indicated in Fig. 4. The collapse of the cutting edge following the junction of the two wear forms (VB) and (KT) appeared as of the rst working minute (Fig. 4a). As cutting time elapsed, general wear accompanied by a series of chippings on the different tool faces developed very quickly and lead to total collapse of the CBN insert within few minutes. As a result, working at high cutting speeds, in particular beyond 280 m/min, the wear phenomenon turn out to be very fast reducing drastically tool life and negatively inuencing

Fig. 1 Flank and crater wear micrographs at Vc = 90 m/min, f = 0.08 mm/rev and ap = 0.5 mm. Machining times: (a) 8 min, (b) 40 min, (c) 56 min and (d) 80 min.

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Fig. 2 Final aspect of crater wear: (a) at beginning of machining, (b) after 80 min of machining at Vc = 120 m/min, f = 0.08 mm/rev, ap = 0.5 mm.

Fig. 3 Flank and crater wear micrographs at Vc = 280 m/min, f = 0.08 mm/rev and ap = 0.5 mm. Machining times: (a) 1.5 min, (b) 7 min, (c) 9 min and (d) 15.5 min.

workpiece surface quality. Under such conditions, tool wear evolves according to several mechanisms. As an indication, both abrasion and diffusion wear mechanisms are generally observed as illustrated for the results obtained by Thiele and Melkote (1999). The rst is due to the friction phenomenon at the interfaces associated to high specic pressures which

are the result of the interaction between machined material hardened phases and the components of the tool. When cutting speeds are high, the interface temperature rises quickly and allows a softening of the tool material, thus engaging the diffusion mechanism that favours chemical reactions. The combination of these two mechanisms accelerates surface

Fig. 4 Flank and crater wear micrographs at Vc = 350 m/min, f = 0.08 mm/rev and ap = 0.5 mm. Machining times: (a) 1.5 min, (b) 2.5 min, (c) 4.5 min and (d) 7.5 min.

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Fig. 7 Tool life of CBN at various cutting speeds.

3.2.

Tool life

Fig. 5 CBN ank wear (VB) evolution as a function of cutting time and speed.

chipping process of the active tool part and degradation of the cutting edge. Figs. 5 and 6 illustrate the evolution of VB and KT of the CBN as a function of cutting time for speeds ranging from 90 to 350 m/min. VB and KT are rather regular and slow at 90 and 120 m/min. In both cases, wear increased in a notable way after 120 m/min but KT increase rate is relatively low compared to that of VB, comforting the fact that VB is considered as the main criterion for tool life assessment. The allowable tool wear ([VB] = 0.3 mm) is reached in 35 min at 180 m/min whereas at 350 m/min the lifespan is only 5 min.

Generally, tool behaviour is inuenced by several factors most importantly the cutting speed. Speed impact on tool lifespan for both allowable wear criteria (i.e. [VB] = 0.3 or 0.4 mm) can be deduced from Fig. 5. The idea of extending the limit value of [VB] to 0.4 mm is supported by microscopic observations of an acceptable surface quality even beyond such a limit which could be economical if the requirements towards dimensional accuracy and surface nish would allow it. For these 2 limiting wear criteria, tool life is extended from 25% to 61% between 90 and 220 m/min whereas, for Vc 220 m/min, it increased by a factor of 1.5 (Fig. 7). For the criterion [VB] = 0.3 mm, speed effect can be interpreted by comparing tool life ratios. The ratio T90 /T120 is only 1.15 whereas T120 /T180 is the double. For speeds above 220 m/min, such ratio reaches an important value of 19.16 indicating a signicant wear which is accentuated by higher temperatures. Consequently, between 280 and 350 m/min, machining becomes unstable after just few minutes as vibrations and continuous sparks make machining thereafter dangerous and even impossible. Globally, it is deduced that cutting speeds higher than 280 m/min should not be recommended for CBN tools in this case because of the very fast wear rate. Results obtained from Fig. 5 allow tool life models to be established based on least square data analysis for the 0.3 and 0.4 mm limit wear criteria. The latter as set according to the cutting speed as the main variable for industrial production. For the cutting speed interval considered in this study, tool life can be described by the following equations:
2.18 T [VB]=0.3 mm = e14.65 Vc 2.02 T [VB]=0.4 mm = e14.14 Vc

(R2 = 0.997) (R2 = 0.996)

(3) (4)

Fig. 6 CBN crater wear (KT) evolution as a function of cutting time and speed.

Eqs. (3) and (4) express quantitative relationship between the life and cutting speed; on one hand, they make it possible to calculate the cutting speed necessary for a preset tool life and on the other hand, to optimize the machining conditions in combination with the relevant cutting regime parameters. The determination coefcients (R2 ) are high enough implying good agreement with experimental results. On the industrial

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Fig. 8 Machined chip volume at different cutting speeds.

level, the inuence of the cutting speed on the productivity, expressed in total machined chip volume is shown in Fig. 8. This volume is calculated according to the following equation: Volume = Vc f ap T (5)

It can be concluded that the optimal cutting speed is for the system CBN-100Cr6 (60HRC) is 120 m/min for the two wear limit criteria. At 0.3 and 0.4 mm values of [VB], the tool cutting edge could produce 336 and 504 cm3 of chip during 80 and 105 min, respectively (Fig. 8).

3.3.

Cutting forces

Tools wear in particular during the machining of hardened materials, takes place under very severe conditions of friction indicating appreciable local cutting forces. It is known that the basis for the determination of the cutting forces is the product of the material removal rate by the cutting specic energy. Indeed, in Kitagawa et al. (1997), the force magnitude in contact surfaces for machine components is very low (in the order of few MPa) with a surrounding temperature below 100 C, whereas in machining contacts it may attain about 10002000 MPa with a temperature ranging from 100 C to above 1000 C. For the given machining system (CBN-100Cr6), the evolution of the cutting forces (F) according to the cutting parameters (i.e. Vc , f and ap ) is presented in Fig. 9ac. An increase in the cutting speed leads to a gradual decrease for the 3 components of the cutting forces (Fr , Fa and Fv ). This is due to temperature rise (more heat is generated) in the cutting area, which softens the metal and thus requires less friction forces (Fig. 9a). It should be noted that the cutting conditions employed did not favour any material adherence on tool cutting edge. It is observed that the forces (N) decreased quickly in the interval 60180 m/min, Fr , Fa and Fv are reduced by 18.40%, 22.31% and 23.72%, respectively; however, these drops are only 11.63%, 9.47% and 7.18% between 180 and 280 m/min. When turning 100Cr6-tempered steel with a cut of depth of 0.2 mm, the radial force (Fr ) becomes dominant when compared to the other components of F. This can be explained by the important stresses exclusively applied on the rounded part of the tool

Fig. 9 (a) Speed effect on cutting forces at ap = 0.2 mm; f = 0.08 mm/rev. (b) Feed rate effect on cutting forces at Vc = 120 m/min; ap = 0.2 mm. (c) Depth of cut effect on cutting forces at Vc = 120 m/min; f = 0.08 mm/rev.

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nozzle which has a radius (R ) of 0.8 mm (i.e. ap is only 1/4 R ). The inuence of the feed rate (f) is given in Fig. 9b as the cutting forces increase with f since the sheared chip section is proportional feed rate. In all feed-rate experiments, the radial force is always dominating but closely followed by the tangential component. Practically, the increase in (f) from 0.08 to 0.16 mm/rev increased the components Fr , Fa and Fv , respectively, by 33%, 51% and 58%. On the other hand, from 0.08 to 0.24 mm/rev, the increase is, respectively, of 50%, 65% and 77% (Fig. 9b). Finally, Fig. 9c shows a quasi-linear increase of the components of F with growing depth of cut (ap ) due to expanded volume of deformed metal during the cutting process. At lower values ap (up to 0.3 mm) Fr is dominating but at 0.4 mm and above, both tangential and axial forces exceed the radial one. It can be understood that at low ap values, cutting is mainly done by the rounded tool nozzle part and at higher ap , metal removal is fullled outside nozzle limit radius, which produces resisting forces in both tangential and axial directions.

3.4.

Roughness evolution

In order to study machined surface quality, roughness characterization is limited to the 3 criteria (Ra , Rz and Rt ). Fig. 10ac illustrates effects of the cutting regime (Vc , ap and f) on workpiece roughness. Basically, Vc improves the surface quality especially for speeds up to 120 m/min (Fig. 10a). Above this limit, roughness is stabilized because of the drop in the cutting forces that translate a relative stability of the machining system. Alternatively, an increase of f or ap deteriorates surface quality with f noted as a determinative factor (Fig. 10b and c). The generated surface comprises helicoid furrows resulting from the tool shape and the form of tool-part movements. Obviously, the printed grooves in the hardened material are deeper and broader as the feed rate is higher implying to work at the lower values of f for surface nish. Importantly, in spite of varying f with a factor of 2.5, the resulting surface qualities obtained with CBN remain always acceptable and can be compared with those of grinding as also found by Remadna and Rigal (2006). Consequently, the cutting regime effects on the measured absolute roughness (Ra ) indicated that changing f from 0.08 to 0.2 mm/rev and ap from 0.2 to 1.0 mm resulted in roughness increase by factors of 5.25 and 1.45, respectively, otherwise, an augmenting Vc from 60 to 180 m/min caused a drop by a factor of 1.6 times.

3.5.

Cutting temperature changes

Hard machining of 100Cr6 steel by CBN is characterized by ow of chips at very high temperature and extremely deformed signs of intensive shearing at cutting edge (Fig. 11). Observations and measurements conrmed that most of the generated heat is dissipated by the intermediate chips as they experienced intensive frictions forces and high plastic deformations for a volume relatively small compared to the tool or the workpiece as noted by OSullivan and Cottrell (2001). Fig. 12 presents recorded temperature evolution according to the machining time for various cutting speeds. At 90 m/min and for a duration of 8 min, the maximum temperatures for the chip, the tool and the part are 574, 95 and 46 C, respectively (Fig. 12a). Chip temperature started stabilizing around

Fig. 10 (a) Cutting speed effect on roughness at ap = 0.2 mm and f = 0.08 mm/rev. (b) Depth of cut effect on roughness at Vc = 90 mm and f = 0.08 mm/rev. (c) Feed rate effect on roughness at Vc = 90 mm and ap = 0.2 mm.

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Fig. 11 Heat dissipation through chip while machining, Vc = 220 m/min.

3 min of machining and similar trends are observed for other cutting speeds (Fig. 12b and c). Indeed, at 180 and 350 m/min and for shorter times (4 and 2 min), the maximum chip temperature reached 620 and 870 C, respectively, while tool and workpiece temperatures varied little (Fig. 12b and c). The ratio of chip to workpiece temperatures (t chip /t wp ) may be as high as 16 times. Consequently, even under hard-turning conditions, heat dissipation through the workpiece remains too small. It should be emphasized that Vc , VB, T (tool life) and t (temperature) are closely interdependent during hard turning owing to the fact that a change in Vc involves a change in temperatures (chip and tool) and a heat diffusion within the tool probably causing variations of its mechanical characteristics ` vis-a-vis wear processes. Cutting-temperature evolutions can provide valuable information on thermal effects in relation to nal workpiece characteristics.

0.12 Fa = e7.01 f 0.23 a1.02 Vc p 0.32 Ra = e4.15 f 1.62 a0.07 Vc p 0.30 Rt = e5.17 f 1.23 a0.08 Vc p 0.28 Rz = e5.18 f 1.36 a0.10 Vc p

(R2 = 0.980) (R2 = 0.990) (R2 = 0.980) (R2 = 0.990)

(8) (9) (10) (11)

where e designates the exponential operator. These equations may be employed to predict, for machining conditions within the limits of the constructed models, both roughness and cutting forces. As expected, tool feed rate remains the preponderant factor for roughness criteria assessment as the associated exponent; i.e. y1 > 1 in Eq. (2). It is interesting to rationalize Eq. (2) by the following relation: R = C3 f y4 (12)

3.6.

Correlations according to wear

In this section, it is intended to correlate both cutting forces and roughness with resulting wear behaviour. Fig. 13 illustrates the evolution of the cutting forces according to VB. It is noted that as wear evolves with cutting times, the corresponding forces show a continuous increase because of larger contact surfaces between the part and the tool. Globally, cutting forces describe 3 zones: (i) the rst 10 min, (ii) between 10 and 22 min and (iii) from 22 up to 32 min. In zone (i), VB reached 0.175 mm and the corresponding % increases in terms of F components (Fr , Fa , Fv ) are 33.3%, 25.1% and 9.5%, respectively. Subsequently in zone (ii), VB attained the allowable wear (i.e. [VB]) of 0.3 mm with a somewhat lower rate and caused Fr , Fa , Fv to increase, respectively, by 11.1%, 16.2%, and 16.0%. Finally, when VB increases from 0.3 to 0.41 mm, Fr , Fa and Fv reached 50%, 26.3% and 10.3%, respectively. During the 32 min of machining at Vc = 180 m/min, f = 0.08 mm/rev and ap = 0.5 mm, the corresponding changes in Fr , Fa , and Fv are successively 150%, 135% and 52%. Using the multifactorial method, the 8 constants of the parametric Eqs. (1) and (2) are obtained from statistical least square analysis:
0.19 Fv = e7.97 f 0.48 a0.81 Vc p 0.16 Fr = e7.18 f 0.31 a0.54 Vc p

with C3 and y4 specic constants and R indifferently representing Ra , Rt or Rz . This approach was applied to the experimental data and a computer-processing program allowed writing the correlations in the form of power functions as indicated in Table 4 for different variables. For roughness study, knowing f and tool geometry, it is possible to calculate the theoretical maximum furrow depth drawn on the machined surface. In turning conditions and for an ideal geometrical tool prole, total surface roughness Rt for f too small compared to nozzle radius (r), the following

Table 4 Models for roughness criteria as separate functions of feed rate, cutting speed and depth of cut Variable
Feed rate (mm/rev)

Model
Ra = 16.161. f1.667 Rt = 53.333. f1.353 Rz = 52.712. f1.423
0.469 Ra = 2.018 Vc 0.408 Rt = 10.825 Vc 0.407 Rz = 9.043 Vc

R2
0.976 0.971 0.967 0.949 0.979 0.949 0.974 0.942 0.985

Cutting speed (m/min)

(R2 = 0.990) (R2 = 0.992)

(6)
Depth of cut (mm)

(7)

Ra = 0.333a0.158 p Rt = 2.451a0.205 p Rz = 2.109a0.203 p

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Fig. 13 Cutting force evolutions as a function of ank wear; Vc = 180 m/min; f = 0.08 mm/rev; ap = 0.5 mm.

equation is derived: Rt(Theoretical) = f2 8r

(13)

Eqs. (10), (12) and (13) are used to calculate total roughness values and to compare them with experimental data. Fig. 14 summarizes the results of the various approaches of total roughness according to feed rate. The parametric models represented by Eqs. (10) and (12) give satisfactory cor-

Fig. 12 Temperature evolution as a function of time and cutting speed at (a) Vc = 90 m/min, (b) Vc = 180 m/min and (c) Vc = 350 m/min.

Fig. 14 Comparison of predicted, experimental and theoretical values of Rt as function f at Vc = 90 m/min and ap = 0.2 mm.

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relations based on experimental results for 90 m/min and ap = 0.2 mm. The one parameter model exhibits a good agreement with both measured experimental data and analytical Eq. (13). On the other side, the multi-parameter model integrating cutting regime conditions remains of unquestionable utility as it considers at the same time the effect of Vc , ap and f. During the wear tests, the corresponding surface quality is recorded in order to establish VB effect on roughness. Fig. 15 illustrates this evolution for 4 cutting speeds (90; 120; 180 and 220 m/min). The analysis concludes that any increase in VB implies some deterioration of the surface quality; however, it should be specied that, as long as wear is regular and does not exceed [VB] = 0.3 mm, roughness (in particular the criterion Ra ) evolves very slowly since Ra does not exceed the 0.5 m at 90 and 120 m/min (Fig. 15a and b). For higher speeds, roughness is subjected to a relative increase, but it remains acceptable (Ra < 1.2 m) as indicated in Fig. 15c and d. Again, the choice

of the standard criterion for wear limit ([VB] = 0.3 mm) is well adapted to describe in a suitable way the CBN tool lifespan. In order to explain the changes in roughness behaviour according to CBN wear, optical micrographs of the tool nozzle were taken at wear levels of 0.11 mm (time t1 ), 0.31 mm (time t2 ) and 0.47 mm (time t3 ) and for 220 m/min cutting speed (Fig. 15d). At t1 = 7 min, the tool wear bandwidth is too small which leads to an almost constant roughness (Ra = 0.29 m). This state is associated with the beginning of regular wear characterized with an abrasion mechanism. However, at t2 = 25 min, the allowable wear limit is reached resulting in an abrupt roughness increase (Ra = 0.54 m). At this stage, tool wear is experiencing a commencement of cutting edge deterioration and announcing relatively signicant effects of the generated heat. Finally, for important wear levels (t3 = 38 min), tool collapse is catastrophic which increases contact surface between the tool and the workpiece and thus, intensifying heating as well as cutting forces. Dominating dif-

Fig. 15 Cutting speed effect on roughness evolution as a function of ank wear for f = 0.08mm/rev; ap = 0.5 mm: (a) Vc = 90 m/min, (b) Vc = 120 m/min, Vc = 180 m/min and (d) Vc = 220 m/min.

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Table 5 Roughness (Ra ) models as a function of ank wear [VB] = 0.3 mm Vc (m/min)
90 120 180 220

Model
Ra = 0.241 e2.80VB Ra = 0.204 e2.11VB Ra = 0.258 e1.67VB Ra = 0.229 e2.9VB

R2
0.973 0.953 0.969 0.865

fusion phenomenon results in a signicant degradation of the machined surface as Ra equals 1.18 m. To understand the interaction, which governs tool wear and workpiece roughness, it is judicious to establish a relation connecting Ra to VB. Although VB and Ra are associated to different parts, it is accepted that the one mutually inuences the other and then, must obey an independent correlation. Data analysis from Fig. 15ad permitted to develop the general correlation: Ra = K exp[(VB)] (14)

At Vc = 360 m/min, the ratio chip to workpiece temperatures is 16. (5) In view of roughness measurements, hard turning may be presented as a real alternative to substitute grinding operations. The established advantages for such substitution are materialized by a shorter production cycle and by working on the same workstation. (6) Roughness is largely inuenced by the feed rate under hard-turning conditions although the theoretical model does not describe rationally this effect. Therefore, the use of parametric models may allow better descriptions of roughness phenomena as a function of various factors. (7) A relation between VB and Ra in the form Ra = K e(VB) is proposed. Coefcients K and vary within the ranges 0.2040.258 and 1.672.90, respectively. It permits the follow-up of tool wear from easily accessible workpiece roughness data. This is a very signicant issue for automated monitoring of industrial machining processes.

The numerical values of the constants K and are summarized in Table 5. This approach offers the possibility of controlling VB using measured values of roughness from the workpiece and at the same time computing the remaining tool lifetime. In other words, for a given machining time, correlation (14) translates into a simpler way the tool behaviour data (difcult to obtain) via 2 constants (K and ).

Acknowledgements
This work was completed in the laboratories LMS (Guelma University, Algeria) and LR3MI (Annaba University, Algeria) in collaboration with LaMCos (CNRS, INSA-Lyon, France). The authors would like to thank the Algerian Ministry of Higher Education and Scientic Research (MESRS) and the Delegated Ministry for Scientic Research (MDRS) for granting nancial support for two CNEPRU Research ProjectsLMS: J2401/03/80/06 (Guelma University) and LR3MI: J-2301/03/04/04 (Annaba University). The authors are thankful to the MDRS whose nancial assistance made possible the acquisition of the piezoelectric dynamometer and the microscopy equipment.

4.

Conclusions

This experimental study allows to draw the main following conclusions: (1) Hard turning of 100Cr6 steel with CBN inserts showed a satisfactory wear resistance for relatively high-cutting speeds. Speeds in the interval 280350 m/min should be less recommended in industrial production because of important wear rates. On the other hand, speeds between 90 and 220 m/min can be taken as the most interesting cutting conditions for the system CBN7020-100Cr6. The optimal productivity was recorded at the speed of 120 m/min for the both limit wear criteria. (2) The radial force component is dominating especially when machining is within the limit of tool nozzle radius. Such nding is in contradiction with what is known from conventional turning as Fr = (0.30.5) Fv . Consequently, the radial force cannot be neglected in characterizing static and dynamic behaviours of such machining system. (3) For the 100Cr6 steel roughness, the machining surface is a function of the local damage form and the wear prole of CBN tool. When augmenting Vc , tool wear increases and leads directly to the degradation of the surface quality. In spite of the evolution of wear up to the allowable limit [VB] = 0.3 mm, Ra did not exceed 0.55 m. (4) The major part of the generated heat at the cutting interface is mainly dissipated through the chip and thus, reducing substantially workpiece and tool temperatures.

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