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J. Manuf. Mater. Process. 2018, 2(2), 27; https://doi.org/10.3390/jmmp2020027

New Observations on High-Speed Machining of Hardened AISI 4340 Steel Using Alumina-Based Ceramic Tools

1
Faculty of Engineering, Department of Mechanical Engineering, McMaster University, Hamilton, ON L8S4L7, Canada
2
Department of Mechanical Design and Production, Technical Research Center, Cairo 11461, Egypt
*
Author to whom correspondence should be addressed.
Received: 1 April 2018 / Revised: 28 April 2018 / Accepted: 30 April 2018 / Published: 3 May 2018
(This article belongs to the Special Issue New Findings and Approaches in Machining Processes)
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Abstract

High-speed machining (HSM) is used in industry to improve the productivity and quality of the cutting operations. In this investigation, pure alumina ceramics with the addition of ZrO2, and mixed alumina (Al2O3 + TiC) tools were used in the dry hard turning of AISI 4340 (52 HRC) at different high cutting speeds of 150, 250, 700 and 1000 m/min. It was observed that at cutting speeds of 150 and 250 m/min, pure alumina ceramic tools had better wear resistance than mixed alumina ones. However, upon increasing the cutting speed from 700 to 1000 m/min, mixed alumina ceramic tools outperformed pure ceramic ones. Scanning electron microscopy (SEM) and X-ray photoelectron spectroscopy (XPS) were used to investigate the worn cutting edges and analyze the obtained results. It was found that the tribo-films formed at the cutting zone during machining affected the wear resistances of the tools and influenced the coefficient of friction at the tool-chip interface. These observations were confirmed by the chip compression ratio results at different cutting conditions. Raising cutting speed to 1000 m/min corresponded to a remarkable decrease in cutting force components in the dry hard turning of AISI 4340 steel. View Full-Text
Keywords: high speed machining; Alumina-based ceramic tools; tool wear; AISI 4340 hardened steel high speed machining; Alumina-based ceramic tools; tool wear; AISI 4340 hardened steel
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Shalaby, M.; Veldhuis, S. New Observations on High-Speed Machining of Hardened AISI 4340 Steel Using Alumina-Based Ceramic Tools. J. Manuf. Mater. Process. 2018, 2, 27.

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