Skip to main content
SpringerLink
Log in

Wear mechanisms of the rough form tools in the automatic screw machine test

  • Published:
Journal of Materials Shaping Technology

Abstract

Tool wear mechanisms of the rough form tools in the automatic screw machine test during machining of bismuth-bearing low carbon resulfurized free machining steel under practical machining conditions were investigated. Four mechanisms, namely mild adhesive wear, abrasive wear, continuous wear, and plastic deformation have been observed to play some roles simultaneously. Mild adhesive wear, which is a wear process taking place during detachment of an adhered chip, is believed to be enhanced by fatigue. Abrasive wear could take place either by oxide inclusions in the workpiece or by the primary carbide particles of the tool freed by some wear mechanisms. Continuous wear has been attributed to some type of atomic process, most probably dissolution of tool material into the chip. On the flank face, continuous, abrasive, and mild adhesive wear are believed to be the major wear mechanisms. On the rake face, continuous wear appears to be the predominant tool wear mechanism. Based on this investigation and consideration of the effect of built-up edge (BUE), reduction of cutting force, optimization of BUE size, stabilization of BUE, and reduction of oxide inclusions are found to be important for reduction of tool wear under practical machining conditions.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. H. Yaguchi and D. Bhattacharya, “An Investigation of Factors Controlling Part Growth and Surface Finish of Form Tools in the Automatic Screw Machine Test,”J. Mat. Shaping Tech., Vol. 5, 1988, p. 231.

    Google Scholar 

  2. E.M. Trent,Metal Cutting, 2nd Ed., Butterworths, London, 1984, p. 96.

    Google Scholar 

  3. S. Soderberg and S. Hogmark, “Wear Mechanisms and Tool Life of High Speed Steels Related to Microstructure,”Wear, Vol. 110, 1986, p. 315.

    Article  Google Scholar 

  4. R.A. Joseph and C. Curtis, Inland Steel Co., private communication, 1987.

  5. J.E. Williams, E.F. Smart, and D.R. Milner, “The Metallurgy of Machining—Part 2: The Cutting of Single-Phase, Two-Phase and Some Free Machining Alloys,”Metallurgia, Vol. 81, 1970, p. 51.

    CAS  Google Scholar 

  6. V.A. Tipnis and R.A. Joseph, “A Study of Plunge (or Form) Machining of Low-Carbon Resulfurized Steel on a Multispindle Automatic Screw Machine: Part 2—Influence of Speed, Feed, and Duration of Cutting on Worn Tool Geometry,”J. Eng. Ind. (Trans. ASME), Vol. 93, 1971, p. 571.

    Google Scholar 

  7. W.J. Wilber, A.W.J. Chisholm, and E.J. Pattinson, “Use of the Scanninng Electron Microscope to Study the Function of Manganese Sulphide Inclusions in Re-sulphurized Free-Machining Steels,” 12th Int. Machine Tool Design Research Conf., 1971, p. 499.

  8. H. Yaguchi, “Effect of MnS Inclusion Size on Machinability of Low-Carbon, Leaded, Resulfurized Free-Machining Steel,”J. Applied Metalworking, Vol. 4, 1986, p. 214.

    Article  CAS  Google Scholar 

  9. R. Milovic and M.L.H. Wise, “Tool Wear in the Machining of Leaded Free-Cutting Steel,” Proc. 25th Machine Tool Design Research Conf., 1985, Birmingham, p. 287.

  10. S. Katayama, Nippon Steel, private communication, 1986.

  11. P.W. Shelton and A.S. Wronski, “Microcracking of High-Speed-Steel Tools during Cutting Metals,”Metals Tech., Vol. 10, 1983, p. 308.

    Google Scholar 

  12. S. Soderberg et al., “Wear Resistance of High-Speed Steel Milling Tools,”Metals Tech., Vol. 10, 1983, p. 471.

    Google Scholar 

  13. R. Milovic and J. Wallbank, “The Machining of Low Carbon Free Cutting Steels with High Speed Steel Tools,”J. Applied Metalworking, Vol. 2, 1983, p. 249.

    Article  CAS  Google Scholar 

  14. A.M. El-Rakayby and B. Mills, “The Role of Primary Carbides in the Wear of High Speed Steels,”Wear, Vol. 112, 1986, p. 327.

    Article  CAS  Google Scholar 

  15. R. Milovic, E.F. Smart, and M.L.H. Wise, “Comparison between Use of TiN-Coated and Uncoated High-Speed Steel and Fine-Grained Cemented Carbide Tools in Cutting of Resulphurized 0.08 wt-%C Free-Cutting Steel,”Mat. Sci. Tech., Vol. 2, 1986, p. 59.

    CAS  Google Scholar 

  16. L. Ahman, B. Stridh, and H. Wisell, “Diffusion and Continuous Wear of High-Speed Steel Cutting Tools,”Mat. Sci. Tech., Vol. 1, 1985, p. 156.

    Google Scholar 

  17. A. Misra and I. Finnie, “A Review of the Abrasive Wear of Metals,”J. Engn. Mat. Tech. (Trans. ASME), Vol. 104, 1982, p. 94.

    Article  CAS  Google Scholar 

  18. H. Wahl, “A Survey of the Field of Wear,”Metalen, Vol. 9, 1954, p. 4.

    Google Scholar 

  19. L.M. Riekels, “Inclusion Characterstics in Resulfurized AISI 1215 Free-Machining Steels with Varying Manganese Contents,” Proc.Influence of Metallurgy on Machinability of Engineering Materials, ASM, 1982, p. 42.

  20. N.P. Sun, “Delamination Theory of Wear,”Wear, Vol. 25, 1973, p. 111.

    Article  Google Scholar 

  21. N.P. Suh, “A Overview of the Delamination Theory of Wear,”Wear, Vol. 44, 1977, p. 1.

    Article  Google Scholar 

  22. N.H. Cook, “Tool Wear and Tool Life,”J. Eng. Ind. (Trans. ASME), Vol. 95, 1973, p. 931.

    Google Scholar 

  23. J.D. Watson, R.H. Davies, and S. Ramalingam, “Experience with the Use of ASTM E618-81 for Machinability Testing of Free Cutting Steel,” Proc. 11th NAMRC, SME, 1983, p. 363.

  24. H. Yaguchi, “Development of Drill Machinability Test for Initial and Limited Screening Purposes,” Proc. 26th Mechanincal Working and Steel Processing Conf., ISS-AIME, 1986, p. 223.

  25. T. Itoh, S. Abeyama, and S. Nakamura, “The Effect of Built-up Edge on Surface Finish and Tool Wear Rate,”Proc. Soc. Precision Mech. Japan, 1976, p. 230.

  26. M.C. Shaw et al., “The Influence of Lead on Metal Cutting Forces and Temperatures,” Trans. ASME, Vol. 79, 1957, p. 1143.

    Google Scholar 

  27. P.T. Aylward, “The Application of Carbide Tooling to the Machining of Free-Cutting Steels in Automatic Bar Machines,”Mechanical Working and Steel Processing IV, AIME, 1965, p. 309.

  28. H. Yaguchi, “The Effects of Soft Additives (Pb, Bi) on Formation of Built-up Edge,”Mat. Sci. Tech., Vol. 4, 1988, p. 926.

    CAS  Google Scholar 

  29. T.H.C. Childs and A.B. Smith, “The Separate Influences of Tool Material Properties and Chip Flow on Tool Flank Wear,”Towrds Improved Performance of Tool Materials, The Metals Soc., 1982, p. 235.

  30. R. Kiessling, “The Influence of Non-Metallic Inclusions on the Properties of Steel,” J. of Metals, October, 1969, p. 48.

  31. B.D. Richardson and A.W.J. Chisholm, “A Study of the Effect of Non-Metallic Inclusions on the Machinability of the Ferrous Materials,” Proc. Inst. Mech. Engrs., Vol. 179, 1964, p. 215.

    Google Scholar 

  32. E.M. Trent, “Cutting Steel and Iron with Cemented Carbide Tools, Part III,”J. Iron Steel Inst., Vol. 201, 1963, p. 1001.

    Google Scholar 

  33. K. Ohgo, “The Adhesion Mechanism of the Built-up Edge and the Layer on the Rake Face of a Cutting Tool,”Wear, Vol. 51, 1978, p. 117.

    Article  CAS  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Research Laboratories, Inland Steel Company, 3001 East Columbus Drive, 46312, East Chicago, IN, USA

    Hiroshi Yaguchi

Authors
  1. Hiroshi Yaguchi
    View author publications

    You can also search for this author in PubMed Google Scholar

Rights and permissions

Reprints and permissions

About this article

Cite this article

Yaguchi, H. Wear mechanisms of the rough form tools in the automatic screw machine test. J. Materials Shaping Technology 6, 171–180 (1989). https://doi.org/10.1007/BF02833769

Download citation

  • Issue Date:

  • DOI: https://doi.org/10.1007/BF02833769

Keywords

Search

Navigation