The development of a surface defect machining method for hard turning processes

Waleed Bin Rashid, Saurav Goel, Xichun Luo, James Ritchie

Research output: Contribution to journalArticle

30 Citations (Scopus)

Abstract

Hard turning (HT) is a material removal process employing a combination of a single point cutting tool and high speeds to machine hard ferrous alloys which exhibit hardness values over 45 HRC. In this paper, a surface defect machining (SDM) method for HT is proposed which harnesses the combined advantages of porosity machining and pulsed laser pre-treatment processing. From previous experimental work, this was shown to provide better controllability of the process and improved quality of the machined surface. While the experiments showed promising results, a comprehensive understanding of this new technique could only be achieved through a rigorous, in depth theoretical analysis. Therefore, an assessment of the SDM technique was carried out using both finite element method (FEM) and molecular dynamics (MD) simulations.

FEM modelling was used to compare the conventional HT of AISI 4340 steel (52 HRC) using an Al2O3 insert with the proposed SDM method. The simulations showed very good agreement with the previously published experimental results. Compared to conventional HT, SDM provided favourable machining outcomes, such as reduced shear plane angle, reduced average cutting forces, improved surface roughness, lower residual stresses on the machined surface, reduced tool–chip interface contact length and increased chip flow velocity. Furthermore, a scientific explanation of the improved surface finish was revealed using a state-of-the-art MD simulation model which suggested that during SDM, a combination of both the cutting action and rough polishing action help improve the machined surface finish.
Original languageEnglish
Pages (from-to)1124-1135
JournalWear
Volume302
Issue number1-2
Early online date23 Jan 2013
DOIs
Publication statusPublished - May 2013

Fingerprint

Surface defects
surface defects
machining
Machining
Molecular dynamics
finite element method
molecular dynamics
harnesses
Finite element method
laser machining
simulation
Iron alloys
Steel
controllability
Computer simulation
Cutting tools
inserts
Polishing
Controllability
Pulsed lasers

Keywords

  • Surface defect machining
  • FEM
  • MD simulation

Cite this

Rashid, Waleed Bin ; Goel, Saurav ; Luo, Xichun ; Ritchie, James. / The development of a surface defect machining method for hard turning processes. In: Wear. 2013 ; Vol. 302, No. 1-2. pp. 1124-1135.
@article{22579fba84a843a092ed2a76c6944ae1,
title = "The development of a surface defect machining method for hard turning processes",
abstract = "Hard turning (HT) is a material removal process employing a combination of a single point cutting tool and high speeds to machine hard ferrous alloys which exhibit hardness values over 45 HRC. In this paper, a surface defect machining (SDM) method for HT is proposed which harnesses the combined advantages of porosity machining and pulsed laser pre-treatment processing. From previous experimental work, this was shown to provide better controllability of the process and improved quality of the machined surface. While the experiments showed promising results, a comprehensive understanding of this new technique could only be achieved through a rigorous, in depth theoretical analysis. Therefore, an assessment of the SDM technique was carried out using both finite element method (FEM) and molecular dynamics (MD) simulations.FEM modelling was used to compare the conventional HT of AISI 4340 steel (52 HRC) using an Al2O3 insert with the proposed SDM method. The simulations showed very good agreement with the previously published experimental results. Compared to conventional HT, SDM provided favourable machining outcomes, such as reduced shear plane angle, reduced average cutting forces, improved surface roughness, lower residual stresses on the machined surface, reduced tool–chip interface contact length and increased chip flow velocity. Furthermore, a scientific explanation of the improved surface finish was revealed using a state-of-the-art MD simulation model which suggested that during SDM, a combination of both the cutting action and rough polishing action help improve the machined surface finish.",
keywords = "Surface defect machining, FEM, MD simulation",
author = "Rashid, {Waleed Bin} and Saurav Goel and Xichun Luo and James Ritchie",
year = "2013",
month = "5",
doi = "10.1016/j.wear.2013.01.048",
language = "English",
volume = "302",
pages = "1124--1135",
journal = "Wear",
issn = "0043-1648",
publisher = "Elsevier BV",
number = "1-2",

}

Rashid, WB, Goel, S, Luo, X & Ritchie, J 2013, 'The development of a surface defect machining method for hard turning processes', Wear, vol. 302, no. 1-2, pp. 1124-1135. https://doi.org/10.1016/j.wear.2013.01.048

The development of a surface defect machining method for hard turning processes. / Rashid, Waleed Bin; Goel, Saurav; Luo, Xichun; Ritchie, James.

In: Wear, Vol. 302, No. 1-2, 05.2013, p. 1124-1135.

Research output: Contribution to journalArticle

TY - JOUR

T1 - The development of a surface defect machining method for hard turning processes

AU - Rashid, Waleed Bin

AU - Goel, Saurav

AU - Luo, Xichun

AU - Ritchie, James

PY - 2013/5

Y1 - 2013/5

N2 - Hard turning (HT) is a material removal process employing a combination of a single point cutting tool and high speeds to machine hard ferrous alloys which exhibit hardness values over 45 HRC. In this paper, a surface defect machining (SDM) method for HT is proposed which harnesses the combined advantages of porosity machining and pulsed laser pre-treatment processing. From previous experimental work, this was shown to provide better controllability of the process and improved quality of the machined surface. While the experiments showed promising results, a comprehensive understanding of this new technique could only be achieved through a rigorous, in depth theoretical analysis. Therefore, an assessment of the SDM technique was carried out using both finite element method (FEM) and molecular dynamics (MD) simulations.FEM modelling was used to compare the conventional HT of AISI 4340 steel (52 HRC) using an Al2O3 insert with the proposed SDM method. The simulations showed very good agreement with the previously published experimental results. Compared to conventional HT, SDM provided favourable machining outcomes, such as reduced shear plane angle, reduced average cutting forces, improved surface roughness, lower residual stresses on the machined surface, reduced tool–chip interface contact length and increased chip flow velocity. Furthermore, a scientific explanation of the improved surface finish was revealed using a state-of-the-art MD simulation model which suggested that during SDM, a combination of both the cutting action and rough polishing action help improve the machined surface finish.

AB - Hard turning (HT) is a material removal process employing a combination of a single point cutting tool and high speeds to machine hard ferrous alloys which exhibit hardness values over 45 HRC. In this paper, a surface defect machining (SDM) method for HT is proposed which harnesses the combined advantages of porosity machining and pulsed laser pre-treatment processing. From previous experimental work, this was shown to provide better controllability of the process and improved quality of the machined surface. While the experiments showed promising results, a comprehensive understanding of this new technique could only be achieved through a rigorous, in depth theoretical analysis. Therefore, an assessment of the SDM technique was carried out using both finite element method (FEM) and molecular dynamics (MD) simulations.FEM modelling was used to compare the conventional HT of AISI 4340 steel (52 HRC) using an Al2O3 insert with the proposed SDM method. The simulations showed very good agreement with the previously published experimental results. Compared to conventional HT, SDM provided favourable machining outcomes, such as reduced shear plane angle, reduced average cutting forces, improved surface roughness, lower residual stresses on the machined surface, reduced tool–chip interface contact length and increased chip flow velocity. Furthermore, a scientific explanation of the improved surface finish was revealed using a state-of-the-art MD simulation model which suggested that during SDM, a combination of both the cutting action and rough polishing action help improve the machined surface finish.

KW - Surface defect machining

KW - FEM

KW - MD simulation

U2 - 10.1016/j.wear.2013.01.048

DO - 10.1016/j.wear.2013.01.048

M3 - Article

VL - 302

SP - 1124

EP - 1135

JO - Wear

JF - Wear

SN - 0043-1648

IS - 1-2

ER -