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Materials 2017, 10(11), 1230; doi:10.3390/ma10111230

Effect of Built-Up Edge Formation during Stable State of Wear in AISI 304 Stainless Steel on Machining Performance and Surface Integrity of the Machined Part

1
McMaster Manufacturing Research Institute (MMRI), Department of Mechanical Engineering, McMaster University, 1280 Main Street West, Hamilton, ON L8S4L7, Canada
2
Department of Mechanical and Materials Science, Catholic University of Santa Catarina, Rua Visconde de Taunay, 427-Centro, Joinville-SC 89203-005, Brazil
*
Author to whom correspondence should be addressed.
Received: 4 October 2017 / Revised: 21 October 2017 / Accepted: 23 October 2017 / Published: 25 October 2017
(This article belongs to the Section Manufacturing Processes and Systems)
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Abstract

During machining of stainless steels at low cutting -speeds, workpiece material tends to adhere to the cutting tool at the tool–chip interface, forming built-up edge (BUE). BUE has a great importance in machining processes; it can significantly modify the phenomenon in the cutting zone, directly affecting the workpiece surface integrity, cutting tool forces, and chip formation. The American Iron and Steel Institute (AISI) 304 stainless steel has a high tendency to form an unstable BUE, leading to deterioration of the surface quality. Therefore, it is necessary to understand the nature of the surface integrity induced during machining operations. Although many reports have been published on the effect of tool wear during machining of AISI 304 stainless steel on surface integrity, studies on the influence of the BUE phenomenon in the stable state of wear have not been investigated so far. The main goal of the present work is to investigate the close link between the BUE formation, surface integrity and cutting forces in the stable sate of wear for uncoated cutting tool during the cutting tests of AISI 304 stainless steel. The cutting parameters were chosen to induce BUE formation during machining. X-ray diffraction (XRD) method was used for measuring superficial residual stresses of the machined surface through the stable state of wear in the cutting and feed directions. In addition, surface roughness of the machined surface was investigated using the Alicona microscope and Scanning Electron Microscopy (SEM) was used to reveal the surface distortions created during the cutting process, combined with chip undersurface analyses. The investigated BUE formation during the stable state of wear showed that the BUE can cause a significant improvement in the surface integrity and cutting forces. Moreover, it can be used to compensate for tool wear through changing the tool geometry, leading to the protection of the cutting tool from wear. View Full-Text
Keywords: stable state of wear; built-up edge; tool wear; surface integrity; cutting forces; AISI 304 stainless steel stable state of wear; built-up edge; tool wear; surface integrity; cutting forces; AISI 304 stainless steel
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MDPI and ACS Style

Ahmed, Y.S.; Fox-Rabinovich, G.; Paiva, J.M.; Wagg, T.; Veldhuis, S.C. Effect of Built-Up Edge Formation during Stable State of Wear in AISI 304 Stainless Steel on Machining Performance and Surface Integrity of the Machined Part. Materials 2017, 10, 1230.

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