Performance of conventional and wiper CBN inserts under various cooling conditions in hard turning of AISI 52100 steel
-
Hüseyin Alp Çetindağ
Hüseyin alp Çetindağ, born in 1993, graduated with a master’s degree from Ankara Yıldırım Beyazıt University in 2019. He is working as a project engineer at Presidency of the Republic of Türkiye Defence Industry Agency since 2018. Currently, he is a PhD candidate at Ankara Yıldırım Beyazıt University and his research focuses on sustainable manufacturing and machining dynamics.
Dr. Adem Çiçek, born in 1973, received his PhD degree in Mechanical Education from Gazi University in 2005. He is a Professor of the Department of Mechanical Engineering at Ankara Yıldırım Beyazıt University since 2012. His research interests include the machinability of engineering materials, artificial intelligence, and materials science.
Dr. Necati Uçak, born in 1990, received his PhD degree in Mechanical Engineering from Ankara Yıldırım Beyazıt University in 2023. He is working as a research assistant at Department of Mechanical Engineering, Ankara Yıldırım Beyazıt University since 2014. His research interests include the machinability of engineering materials, additive manufacturing, and finite element modeling.
und
Kubilay Aslantas
Dr. Kubilay Aslantas, born in 1974, received his PhD degree in Mechanical Education from Gazi University in 2003. He is a Professor of the Department of Mechanical Engineering at Afyon Kocatepe University since 2011. His research interests include high speed machining, modeling of machining, micro machining, machinability evaluation, and machining process monitoring.
Abstract
Cryogenic cooling and minimum quantity lubrication (MQL) are regarded as effective green manufacturing techniques since they eliminate the excessive utilization of conventional cutting fluids (CCFs) that are known to have adverse impacts on both the environment and human health. Moreover, these methods have promising effects on surface integrity in machining hard-to-cut materials. This study investigates the impact of hybrid and cryogenic lubri-cooling methods on surface integrity (surface roughness, microhardness, and residual stresses) in hard turning of AISI 52100 bearing steel (62 HRC) with conventional and wiper CBN inserts. For that purpose, a precooling-based hybrid (a combination of precryogenic cooling of the workpiece and MQL) and direct cryogenic cooling techniques were used for comparison during the hard turning tests. The tests were carried out at a constant cutting speed (200 m/min), feed (0.1 mm∙rev−1), and depth of cut (0.1 mm) under dry, carbon dioxide (CO2), liquid nitrogen (LN2), CO2 + MQL, and LN2 + MQL conditions. The results show that hybrid lubri-cooling condition (CO2 + MQL) improved the surface quality and increased the compressive residual stresses at the machined surface when wiper inserts were employed. On the other hand, effective cooling under direct CO2 condition provided better surface integrity when machining with conventional inserts.
Funding source: Ankara YÄldÄrÄm BeyazÄt Ãœniversitesi
Award Identifier / Grant number: 4767
About the authors
Hüseyin alp Çetindağ, born in 1993, graduated with a master’s degree from Ankara Yıldırım Beyazıt University in 2019. He is working as a project engineer at Presidency of the Republic of Türkiye Defence Industry Agency since 2018. Currently, he is a PhD candidate at Ankara Yıldırım Beyazıt University and his research focuses on sustainable manufacturing and machining dynamics.
Dr. Adem Çiçek, born in 1973, received his PhD degree in Mechanical Education from Gazi University in 2005. He is a Professor of the Department of Mechanical Engineering at Ankara Yıldırım Beyazıt University since 2012. His research interests include the machinability of engineering materials, artificial intelligence, and materials science.
Dr. Necati Uçak, born in 1990, received his PhD degree in Mechanical Engineering from Ankara Yıldırım Beyazıt University in 2023. He is working as a research assistant at Department of Mechanical Engineering, Ankara Yıldırım Beyazıt University since 2014. His research interests include the machinability of engineering materials, additive manufacturing, and finite element modeling.
Dr. Kubilay Aslantas, born in 1974, received his PhD degree in Mechanical Education from Gazi University in 2003. He is a Professor of the Department of Mechanical Engineering at Afyon Kocatepe University since 2011. His research interests include high speed machining, modeling of machining, micro machining, machinability evaluation, and machining process monitoring.
Acknowledgments
The authors thank the ORS (Ortadoğu Rulman Sanayi) Company for residual stress measurements and specimen preparation.
-
Research ethics: Not applicable.
-
Author contributions: All the authors have accepted responsibility for the entire content of this submitted manuscript and approved submission.
-
Competing interests: The authors declare no conflicts of interest regarding this article.
-
Research funding: This work was supported by Ankara Yıldırım Beyazıt University, Scientific Research Project Division [grant number: 4767].
-
Data availability: The raw data can be obtained on request from the corresponding author.
References
[1] A. D. Jayal, F. Badurdeen, O. W. Dillon, and I. S. Jawahir, “Sustainable manufacturing: modeling and optimization challenges at the product, process and system levels,” CIRP J. Manuf. Sci. Technol., vol. 2, no. 3, pp. 144–152, 2010, https://doi.org/10.1016/j.cirpj.2010.03.006.Suche in Google Scholar
[2] I. S. Jawahir, H. Attia, D. Biermann, et al.., “Cryogenic manufacturing processes,” CIRP Annals, vol. 65, no. 2, pp. 713–736, 2016, https://doi.org/10.1016/j.cirp.2016.06.007.Suche in Google Scholar
[3] Chetan, S. Ghosh, and P. Venkateswara Rao, “Application of sustainable techniques in metal cutting for enhanced machinability: a review,” J. Clean. Prod., vol. 100, pp. 17–34, 2015, https://doi.org/10.1016/j.jclepro.2015.03.039.Suche in Google Scholar
[4] M. Dix, R. Wertheim, G. Schmidt, and C. Hochmuth, “Modeling of drilling assisted by cryogenic cooling for higher efficiency,” CIRP Annals, vol. 63, no. 1, pp. 73–76, 2014, https://doi.org/10.1016/j.cirp.2014.03.080.Suche in Google Scholar
[5] M. Biček, F. Dumont, C. Courbon, F. Pušavec, J. Rech, and J. Kopač, “Cryogenic machining as an alternative turning process of normalized and hardened AISI 52100 bearing steel,” J. Mater. Process. Technol., vol. 212, no. 12, pp. 2609–2618, 2012, https://doi.org/10.1016/j.jmatprotec.2012.07.022.Suche in Google Scholar
[6] G. Rotella, O. W. Dillon, D. Umbrello, L. Settineri, and I. S. Jawahir, “The effects of cooling conditions on surface integrity in machining of Ti6Al4V alloy,” Int. J. Adv. Des. Manuf. Technol., vol. 71, nos. 1–4, pp. 47–55, 2014, https://doi.org/10.1007/s00170-013-5477-9.Suche in Google Scholar
[7] M. M. Fallah and F. Jafarian, “Cryogenic and dry machining of Ti6Al4V Alloy for evaluation of microhardness, thermal loads, microstructure, and surface quality,” J. Mater. Eng. Perform., vol. 32, pp. 5895–5905, 2022, https://doi.org/10.1007/s11665-022-07512-x.Suche in Google Scholar
[8] F. Pusavec, A. Deshpande, S. Yang, et al.., “Sustainable machining of high temperature nickel alloy – Inconel 718: part 1 – predictive performance models,” J. Clean. Prod., vol. 81, pp. 255–269, 2014, https://doi.org/10.1016/j.jclepro.2014.06.040.Suche in Google Scholar
[9] B. D. Jerold and M. P. Kumar, “Machining of AISI 316 stainless steel under carbon-di-oxide cooling,” Mater. Manuf. Processes, vol. 27, no. 10, pp. 1059–1065, 2012, https://doi.org/10.1080/10426914.2011.654153.Suche in Google Scholar
[10] H. A. Çetindağ, A. Çiçek, and N. Uçak, “The effects of CryoMQL conditions on tool wear and surface integrity in hard turning of AISI 52100 bearing steel,” J. Manuf. Process., vol. 56, pp. 463–473, 2020, https://doi.org/10.1016/j.jmapro.2020.05.015.Suche in Google Scholar
[11] A. Damir, B. Shi, and M. H. Attia, “Flow characteristics of optimized hybrid cryogenic-minimum quantity lubrication cooling in machining of aerospace materials,” CIRP Annals, vol. 68, no. 1, pp. 77–80, 2019, https://doi.org/10.1016/j.cirp.2019.04.047.Suche in Google Scholar
[12] O. Özbek, N. Altan Özbek, F. Kara, and H. Saruhan, “Effect of vibration and cutting zone temperature on surface topography during hybrid cooling/lubrication assisted machining of Vanadis 10,” Mater. Test., vol. 65, no. 9, pp. 1437–1452, 2023, https://doi.org/10.1515/mt-2023-0057.Suche in Google Scholar
[13] S. Sartori, A. Ghiotti, and S. Bruschi, “Hybrid lubricating/cooling strategies to reduce the tool wear in finishing turning of difficult-to-cut alloys,” Wear, vol. 376, no. 377, pp. 107–114, 2017, https://doi.org/10.1016/j.wear.2016.12.047.Suche in Google Scholar
[14] A. Bagherzadeh and E. Budak, “Investigation of machinability in turning of difficult-to-cut materials using a new cryogenic cooling approach,” Tribol. Int., vol. 119, pp. 510–520, 2018, https://doi.org/10.1016/j.triboint.2017.11.033.Suche in Google Scholar
[15] D. A. Stephenson, S. J. Skerlos, A. S. King, and S. D. Supekar, “Rough turning Inconel 750 with supercritical CO2-based minimum quantity lubrication,” J. Mater. Process. Technol., vol. 214, no. 3, pp. 673–680, 2014, https://doi.org/10.1016/j.jmatprotec.2013.10.003.Suche in Google Scholar
[16] R. Mallick, R. Kumar, A. Panda, and A. K. Sahoo, “Current status of hard turning in manufacturing: aspects of cooling strategy and sustainability,” Lubricants, vol. 11, no. 3, p. 108, 2023, https://doi.org/10.3390/lubricants11030108.Suche in Google Scholar
[17] S. Kokkirala, J. Holmberg, U. Klement, R. Lundstrom, H. Iwasaki, and S. B. Hosseini, “Effect of cutting parameters on the generated surface integrity of hard-turned martensitic AISI 52100 bearing steel,” Procedia CIRP, vol. 115, pp. 154–159, 2022, https://doi.org/10.1016/j.procir.2022.10.066.Suche in Google Scholar
[18] D. Murat, C. Ensarioglu, N. Gursakal, A. Oral, and M. C. Cakir, “Surface roughness analysis of greater cutting depths during hard turning,” Mater. Test., vol. 59, no. 9, pp. 795–802, 2017, https://doi.org/10.3139/120.111074.Suche in Google Scholar
[19] D. Umbrello, F. Micari, and I. S. Jawahir, “The effects of cryogenic cooling on surface integrity in hard machining: a comparison with dry machining,” CIRP Annals, vol. 61, no. 1, pp. 103–106, 2012, https://doi.org/10.1016/j.cirp.2012.03.052.Suche in Google Scholar
[20] W. Grzesik, Advanced Machining Processes of Metallic Materials, 2nd ed., Oxford, Elsevier, 2017.10.1016/B978-0-444-63711-6.00015-6Suche in Google Scholar
[21] E. Tan, I. Ovali, A. Mavi, M. Kaplan, and Ş. Okay, “Influence of repeated tempering on the machinability and microstructure of an AISI 52100 steel,” Mater. Test., vol. 57, nos. 11–12, pp. 947–953, 2015, https://doi.org/10.3139/120.110805.Suche in Google Scholar
[22] W. Ankener, M. Smaga, J. Uebel, et al.., “Depth-resolved characterization of cryogenic hard turned surface layer of AISI 52100 by X-ray diffraction and scanning electron microscopy investigations,” Procedia CIRP, vol. 108, pp. 66–71, 2022, https://doi.org/10.1016/j.procir.2022.03.015.Suche in Google Scholar
[23] W. Zhang and K. Zhuang, “Effect of cutting edge microgeometry on surface roughness and white layer in turning AISI 52100 steel,” Procedia CIRP, vol. 87, pp. 53–58, 2020, https://doi.org/10.1016/j.procir.2020.02.079.Suche in Google Scholar
[24] D. M. Kim, H. I. Kim, and H. W. Park, “Tool wear, economic costs, and CO2 emissions analysis in cryogenic assisted hard-turning process of AISI 52100 steel,” Sustain. Mater. Technol., vol. 30, 2021, Art. no. e00349, https://doi.org/10.1016/j.susmat.2021.e00349.Suche in Google Scholar
[25] I. Urresti, I. Llanos, J. Zurbitu, and O. Zelaieta, “Tool wear modelling of cryogenic-assisted hard turning of AISI 52100,” Procedia CIRP, vol. 102, pp. 494–499, 2021, https://doi.org/10.1016/j.procir.2021.09.084.Suche in Google Scholar
[26] P. Sivaiah, M. Guru Prasad, M. Singh, and B. Uma, “Machinability evaluation during machining of AISI 52100 steel with textured tools under Minimum Quantity Lubrication – a comparative study,” Mater. Manuf. Processes, vol. 35, no. 15, pp. 1761–1768, 2020, https://doi.org/10.1080/10426914.2020.1802034.Suche in Google Scholar
[27] H. A. Çetindağ, “An investigation on the influence of different cooling/lubrication techniques on the tool wear and surface integrity in the hard turning of AISI 52100 bearing steel,” MSc dissertation, Department of Mechanical Engineering, Ankara Yıldırım Beyazıt University, Ankara, Türkiye, 2019.Suche in Google Scholar
[28] B. D. Jerold and M. P. Kumar, “Experimental comparison of carbon-dioxide and liquid nitrogen cryogenic coolants in turning of AISI 1045 steel,” Cryogenics, vol. 52, no. 10, pp. 569–574, 2012, https://doi.org/10.1016/j.cryogenics.2012.07.009.Suche in Google Scholar
[29] S. Y. Hong and Y. Ding, “Cooling approaches and cutting temperatures in cryogenic machining of Ti-6Al-4V,” Int. J. Mach. Tool Manufact., vol. 41, no. 10, pp. 1417–1437, 2001, https://doi.org/10.1016/S0890-6955(01)00026-8.Suche in Google Scholar
[30] A. Shokrani, V. Dhokia, P. Muñoz-Escalona, and S. T. Newman, “State-of-the-art cryogenic machining and processing,” Int. J. Comput. Integrated Manuf., vol. 26, no. 7, pp. 616–648, 2013, https://doi.org/10.1080/0951192X.2012.749531.Suche in Google Scholar
[31] T. C. Yap, A. Sivaraos, C. S. Lim, and J. W. Leau, “Surface roughness and cutting forces in cryogenic turning of carbon steel,” J. Eng. Sci. Technol., vol. 10, no. 7, pp. 911–920, 2015.Suche in Google Scholar
[32] P. R. Zhang, Z. Q. Liu, and Y. B. Guo, “Machinability for dry turning of laser cladded parts with conventional vs. wiper insert,” J. Manuf. Process., vol. 28, no. 3, pp. 494–499, 2017, https://doi.org/10.1016/j.jmapro.2017.04.017.Suche in Google Scholar
[33] M. Neslusan, M. Faktor, and M. Cillikova, “Analysis of surface integrity after hard turning with wiper inserts,” MM Sci. J., vol. 2014, no. 03, pp. 481–484, 2014, https://doi.org/10.17973/MMSJ.2014_10_201409.Suche in Google Scholar
[34] S. Wu, G. Liu, W. Zhang, W. Chen, and C. Wang, “Formation mechanism of white layer in the high-speed cutting of hardened steel under cryogenic liquid nitrogen cooling,” J. Mater. Process. Technol., vol. 302, 2022, Art. no. 117469, https://doi.org/10.1016/j.jmatprotec.2021.117469.Suche in Google Scholar
[35] F. Careri, S. Imbrogno, D. Umbrello, M. M. Attallah, J. Outeiro, and A. C. Batista, “Machining and heat treatment as post-processing strategies for Ni-superalloys structures fabricated using direct energy deposition,” J. Manuf. Process., vol. 61, pp. 236–244, 2021, https://doi.org/10.1016/j.jmapro.2020.11.024.Suche in Google Scholar
[36] A. Chavan and V. Sargade, “Surface integrity of AISI 52100 steel during hard turning in different near-dry environments,” Adv. Mater. Sci. Eng., vol. 2020, pp. 1–13, 2020, https://doi.org/10.1155/2020/4256308.Suche in Google Scholar
© 2023 Walter de Gruyter GmbH, Berlin/Boston
Artikel in diesem Heft
- Frontmatter
- User independent tool for the analysis of data from tensile testing for database systems
- Evaluation of corrugated core configuration effects on low-velocity impact response in metallic sandwich panels
- Effect of total heat input on coaxiality of rotor shaft in laser cladding
- Determination of characteristic properties of Co3O4 loaded LaFe x Al12−x O19 hexaaluminates
- Investigation on quasi-static axial crushing of Al/PVC foam-filled Al6063-T5 tubes
- Experimental analysis of the effects of different production directions on the mechanical characteristics of ABS, PLA, and PETG materials produced by FDM
- Interfacial microstructure and mechanical properties of Si3N4/Invar joints using Ag–Cu–In–Ti with Cu foil as an interlayer
- Properties of chemically foamed polypropylene materials for application to automobile interior door panels
- Tribological and thermal characteristics of copper-free brake friction composites
- Dry tribological behaviour of microwave-assisted sintered AA2024 matrix hybrid composites reinforced by TiC/B4C/nano-graphite particles
- Erosion rate of AA6082-T6 aluminum alloy subjected to erosive wear determined by the meta-heuristic (SCA) based ANFIS method
- Mechanical properties of elevator ropes and belts exposed to corrosion and elevated temperatures
- Variants of friction stir based processes: review on process fundamentals, material attributes and mechanical properties
- Performance of conventional and wiper CBN inserts under various cooling conditions in hard turning of AISI 52100 steel
Artikel in diesem Heft
- Frontmatter
- User independent tool for the analysis of data from tensile testing for database systems
- Evaluation of corrugated core configuration effects on low-velocity impact response in metallic sandwich panels
- Effect of total heat input on coaxiality of rotor shaft in laser cladding
- Determination of characteristic properties of Co3O4 loaded LaFe x Al12−x O19 hexaaluminates
- Investigation on quasi-static axial crushing of Al/PVC foam-filled Al6063-T5 tubes
- Experimental analysis of the effects of different production directions on the mechanical characteristics of ABS, PLA, and PETG materials produced by FDM
- Interfacial microstructure and mechanical properties of Si3N4/Invar joints using Ag–Cu–In–Ti with Cu foil as an interlayer
- Properties of chemically foamed polypropylene materials for application to automobile interior door panels
- Tribological and thermal characteristics of copper-free brake friction composites
- Dry tribological behaviour of microwave-assisted sintered AA2024 matrix hybrid composites reinforced by TiC/B4C/nano-graphite particles
- Erosion rate of AA6082-T6 aluminum alloy subjected to erosive wear determined by the meta-heuristic (SCA) based ANFIS method
- Mechanical properties of elevator ropes and belts exposed to corrosion and elevated temperatures
- Variants of friction stir based processes: review on process fundamentals, material attributes and mechanical properties
- Performance of conventional and wiper CBN inserts under various cooling conditions in hard turning of AISI 52100 steel
