Inclusion modification of steels the theory

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Historical analysis of metal cutting shows that metal removal rates have been increasing in the course of the century, predicated by the advancement in tool materials but the steel design has lagged behind. This paper examines the mechanisms of chip formation and tool wear as a function of cutting speed in metal cutting. Chemical wear is identified as the dominant mechanism of tool wear at high cutting speeds caused by temperature rise due to shear localisation in the primary and secondary shear zones of chip. Shear localisation in the primary shear zone is shown to be influenced by both microstructural parameters, i.e. matrix hardening and second phase particles, and metal cutting variables, i.e. cutting speed (strain rate) and feed (pressure).

Design of steels for high speed machining

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Purpose – This paper seeks to evaluate the influence of tellurium content on the machinability of the microalloyed pearlitic steel (DIN 38MnS6). Two grades of steels were used, one with high (27 times greater) tellurium content and one with a low tellurium content. Machinability of the steel was determined by the number of holes drilled by the tool before undergoing severe deformation. The drilling test matrix was prepared using a fractional factorial design with five input variables studied at two levels (25-1). Other variables investigated include cutting speed (45 and 60 m/min), feed rate (0.15 and 0.25 mm/rev), geometry of the twist drills and use of minimum quantity lubrication (MQL) at the flow rates of 30 and 100 ml/h. Statistical analysis of the results revealed that composition of the work material was most influential on tool performance. Addition of tellurium to the steel significantly improved machinability, increasing the number of drilled holes by over 100 per cent. The MQL flow rate was the least influential as increase in the flow from 30 to 100 ml/h reduced drill life only by about 9 per cent. Design/methodology/approach – The drilling tests were carried out in the vertical position, up-down, without pre-holes (full drilling). Cutting speeds of 45 and 60 m/min and feed rates of 0.15 and 0.25 mm/rev were employed. Drills with two sharpening types were tested. Cutting fluid used was vegetable based and applied using the MQL technique at flow rates of 30 and 100 ml/h. The rejection criterion adopted was severe deformation of the drills and the number of machined holes was used to measure the machinability of the material. Findings – Of all the variables investigated in this study, the least influential on drill performance is the MQL flow rate. Increase in the flow rate from 30 to 100 ml/h reduced drill performance by 9 per cent, contrary to expectation. This is a result of the cooling-lubricant action balance promoted by the cutting fluid applied in low quantities (MQL). The most influential variable on drill performance is addition of Te to the work material which gave over twofold (103 per cent) improvement in drill performance at the cutting conditions investigated. The Te particles act at the chip-tool interface, reducing the work necessary to shear the material during chip formation. Increase in both the cutting speed and the feed rate both lowered drill performance during machining due to associated increase in cutting temperature which tended to accelerate thermally related wear mechanisms. Originality/value – This work was conducted to evaluate the machinability of a novel alloyed steel employed in the automobile industry. Drilling was considered as most automobile components especially the engine block is designed with many holes which require drilling process.

Influence of tellurium addition on drilling of microalloyed steel (din 38mns6)

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A fabricação de moldes de grande porte exige a produção na aciaria de lingotes de dimensões acima do usual. De forma a garantir a polibilidade do produto acabado, o material não pode apresentar forte segregação, nível elevado de inclusões não metálicas ou porosidades. Para tanto, é necessária a obtenção de reduzidos teores de enxofre e a execução de elevada deformação mecânica no processo de conformação, principalmente em se tratando de grandes lingotes. Contudo, a redução do teor de enxofre prejudica a usinabilidade o que, sem outras alterações, encarece a fabricação do molde. Neste trabalho, é apresentada a tecnologia de fabricação do bloco para o maior molde já produzido com aço manufaturado no Brasil no qual o teor de enxofre foi reduzido abaixo de 50 ppm e a usinabilidade foi mantida através da modificação da morfologia das inclusões através da desoxidação por cálcio.

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A study was undertaken to investigate the mechanisms of alumina/TiC cutting tool wear in the finish turning of hardened steels with particular cognisance of the work material inclusion content. A six-fold variation in tool life was observed when machining different heats of BS 817M40 steel (similar to AISI 4340) of 52 HRC. In machining steels containing Ca-bearing mixed oxide inclusions, a reaction between the alumina phase of the tool and oxide inclusionary deposits is the dominant wear mechanism. In machining steels containing very low levels of Ca or steels with a very low inclusion content, tool wear appears to be largely based on superficial plastic deformation of the tool surface. The rate of tool wear appears to be determined by the hard inclusion content or alloy carbide content of the work material. Impingement of hard particles against the tool surface are thought to result in the generation of transient localised stresses which exceed the average contact pressures and, thus, either facilitate the operation of additional slip systems or overcome the increases in the critical resolved shear stresses on active slip systems due to prior strain. The influence of saw-tooth chip formation on cutting tool wear is also considered. © 2001 Elsevier Science B.V. All rights reserved.

Cutting tool wear in the machining of hardened steels. part i alumina.ti c cu...

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Cutting of hardened steel is a topic of high interest for toda 's industrial production and scientific research. Machine parts consisting of hardened steel are high peiormance components which are often loaded near their physical limits. The functional behavior of machined parts is decisively influenced by the fine finishing process which represents the last step in the process chain and can as well be undertaken by cutting as grinding. An overview of the mechanisms of chip removal in hard cutting and the thermomechanical influence of the work area is presented. Furthermore, several models of chip removal in hard turning are introduced and discussed summarizing the metallurgical fundamentals and giving an overview on stress and temperature distributions in the work area. Boundary conditions for hard cutting as e.g. machine tools, cutting materials and others are subject to discussion to determine the achievable workpiece quality and economic efficiency of hard cutting processes in comparison with grinding.

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Surface residual stresses due to turning operations in AISI 304 type stainless steel were studied as a function of machining speed, feed rate, depth of cut, and tool geometry and coating. Residual stress tensors were determined using X-ray diffraction technique. The effects of turning conditions and tool on the residual stresses were discussed in terms of mechanically and thermally induced non-homogeneous plastic deformation of the surface layers of the workpiece.

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