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Influence of tool hardness on tool wear, surface roughness and acoustic emissions during turning of AISI 1050

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Surface Topography: Metrology and Properties
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Abstract and Figures

In this work, chemical vapor deposition (CVD) coated carbide inserts with different hardness of P types entitled as hard, semi-hard and tough are utilized for turning of AISI 1050 steel. Flank wear, surface roughness, cutting force, acoustic emissions and chips morphology were considered under dry turning conditions for the comparison of the effect of cutting speed, feed rate and cutting tool hardness. The novelty of the study is to investigate comprehensively the effect of tool hardness along with cutting parameters on the the machinability characteristics. This approach provides to understand the underlying mechanism of tool wear and its influence on the surface properties of the workpiece which is useful in practice for upgraded machinability. The results indicated that the tool hardness affects flank wear dramatically followed by surface roughness and acoustic emissions values and ideal values of cutting conditions are attained with semi-hard tool. Scanning electron microscope (SEM), energy dispersive spectrum (EDX) and mapping analysis also demonstrated the wear developments are distinctive with using different types of tool hardness values. The findings depicted that tool hardness has significant impact on machining characteristics which need to be dealed under particular cutting conditions. 65 HRC of cutting tool provides better machinability in terms of surface roughness, tool wear, acoustic emissions and cutting forces followed by 60 HRC and 70 HRC respectively.
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Surf. Topogr.: Metrol. Prop. 10 (2022)015016 https://doi.org/10.1088/2051-672X/ac4f38
PAPER
Inuence of tool hardness on tool wear, surface roughness and
acoustic emissions during turning of AISI 1050
Mustafa Kuntoğlu
1,
, Munish Kumar Gupta
2
, Abdullah Aslan
3
, Emin Salur
4
and A Garcia-Collado
5
1
Selcuk University, Technology Faculty, Mechanical Engineering Department, Konya, 42130, Turkey
2
Faculty of Mechanical Engineering, Opole University of Technology, 76 Proszkowska St., 45-758 Opole,8 Poland
3
Selcuk University, Engineering Faculty, Mechanical Engineering Department, Akşehir, 42550, Turkey
4
Technology Faculty, Metallurgical and Material Engineering Department, Selcuk University, Selçuklu, Konya, 42130, Turkey
5
Department of Mechanical and Mining Engineering, University of Jaen, EPS de Jaen, Campus Las Lagunillas,071 Jaen, Spain
Author to whom any correspondence should be addressed.
E-mail: mkuntoglu@selcuk.edu.tr,munishguptanit@gmail.com,aaslan@selcuk.edu.tr,esalur@selcuk.edu.tr and acollado@ujaen.es
Keywords: Acoustic emissions, cutting forces, surface roughness, tool hardness, ank wear
Abstract
In this work, chemical vapor deposition (CVD)coated carbide inserts with different hardness of P
types entitled as hard, semi-hard and tough are utilized for turning of AISI 1050 steel. Flank wear,
surface roughness, cutting force, acoustic emissions and chips morphology were considered under dry
turning conditions for the comparison of the effect of cutting speed, feed rate and cutting tool
hardness. The novelty of the study is to investigate comprehensively the effect of tool hardness along
with cutting parameters on the the machinability characteristics. This approach provides to
understand the underlying mechanism of tool wear and its inuence on the surface properties of the
workpiece which is useful in practice for upgraded machinability. The results indicated that the tool
hardness affects ank wear dramatically followed by surface roughness and acoustic emissions values
and ideal values of cutting conditions are attained with semi-hard tool. Scanning electron microscope
(SEM), energy dispersive spectrum (EDX)and mapping analysis also demonstrated the wear
developments are distinctive with using different types of tool hardness values. The ndings depicted
that tool hardness has signicant impact on machining characteristics which need to be dealed under
particular cutting conditions. 65 HRC of cutting tool provides better machinability in terms of surface
roughness, tool wear, acoustic emissions and cutting forces followed by 60 HRC and 70 HRC
respectively.
Nomenclature
AISI American Iron and Steel
Institute
CVD Chemical Vapor
Deposition
SEM Scanning Electron
Microscope
ISO International Organiza-
tion for Standardization
HRC Hardness of Rockwell
V
w
The Loss of Material
Volume
K Probability Constant
t Unit Time
v
c
Cutting Speed
N Normal Load
H
t
Tool Hardness
x, k, C Constants
H
a
Abrasive Particle
Hardness
D Particle Diameter
D Averaged Space Between
Particles
f
v
The Volume Fraction of
Particles
z The Probability of Unda-
maged Particles
D Material Constant
RECEIVED
21 December 2021
REVISED
14 January 2022
ACCEPTED FOR PUBLICATION
26 January 2022
PUBLISHED
8 February 2022
© 2022 IOP Publishing Ltd
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