Abstract
Turning of sintered carbide parts has not been a common theme in the literature such as the case of other hardened materials. This is a statement made on the basis of recent research on this subject in which journals and conference proceedings were consulted. However, cutting of sintered cemented carbide parts, especially the turning operation, is an important task for a large number of applications where the typical properties of these materials are required. Therefore, the aim of this research was to carry out internal turning experiments in the manufacture of sintered cemented carbide dies used to forge beer cans. The focus of the experiments was to measure and analyze the workpiece surface roughness and wear of cutting edges used in internal turning process. Therefore, samples of sintered cemented carbide WC–Co (12% Co) were submitted to internal turning process with PCD insert tool. Cutting speed and feed rate were used as input variables in the experiments. It was found that, neither very low cutting speeds, nor high feeds can be used to avoid early breakage of the tool. Moreover, for the experiments where no early tool breakage occurred, the increase of feed caused the number of cutting passes prior to the cutting edge breakage to decrease and the workpiece surface roughness to increase. The experiments performed in this work confirm that sintered cemented carbide internal turning, besides being viable, is also feasible to be used to replace grinding operations, at least in terms of surface quality obtained.
Similar content being viewed by others
References
Belmonte M, Ferro P, Fernandes AJS, Costa FM, Sacramento J, Silva RF (2003) Wear resistant CVD diamonds tools for turning of sintered hard metals. Diam Relat Mater 12(3–7):233–1268
Coppini NL, Diniz AE, Bonandi M, de Souza EM, Baptista EA (2013) Hard turning of sintered cemented carbide parts: a shop floor experience. Proc CIRP 8:368–373
Zębala W, Kowalczyk R, Matras A (2015) Analysis and optimization of sintered carbides turning with PCD tools. Proc Eng 100:283–290. https://doi.org/10.1016/j.proeng.2015.01.369
Aouici H, Yallese MA, Chaoui K, Mabrouki T, Rigal JF (2011) Analysis of surface roughness and cutting force components in hard turning with CBN tool: prediction model and cutting conditions optimization. Measurement 45:344–353. https://doi.org/10.1016/j.measurement.2011.11.011
Godoy VAA, de Diniz AE (2011) Turning of interrupted and continuous hardened steel surfaces using ceramic and CBN cutting tools. J Mater Process Technol 211:1014–1025. https://doi.org/10.1016/j.jmatprotec.2011.01.002
Kaçal A, Yildirim F (2013) High speed hard turning of AISI S1 (60WCrV8) Cold work tool steel. Acta Polytech Hung 10(8):169–186
Bartarya G, Choudhury SK (2012) State of the art in hard turning. Int J Mach Tools Manuf 53:1–14. https://doi.org/10.1016/j.ijmachtools.2011.08.019
Chinchanikar S, Choudhury SK (2015) Machining of hardened steel—experimental investigations, performance modeling and cooling techniques: a review. Int J Mach Tools Manuf 89:95–109. https://doi.org/10.1016/j.ijmachtools.2014.11.002
Chinchanikar S, Choudhury SK (2013) Effect of work material hardness and cutting parameters on performance of coated carbide tool when turning hardened steel: An optimization approach. Measurement 46:1572–1584. https://doi.org/10.1016/j.measurement.2012.11.032
Sahoo AK, Orra K, Routra BC (2013) Application of response surface methodology on investigating flank wear in machining hardened steel using PVD TiN coated mixed ceramic insert. Int J Ind Eng Comput 4:469–478. https://doi.org/10.5267/j.ijiec.2013.07.001
Kuljanic E, Sortino M, Totis G (2010) Machinability of difficult machining materials. In: 14th International research—trends in the development of machinery and associated technology
Suresh R, Basavarajappa S, Gaitonde VN, Samuel GL (2012) Machinability investigations on hardened AISI 4340 steel using coated carbide insert. Int J Refract Metal Hard Mater 33:75–86. https://doi.org/10.1016/j.ijrmhm.2012.02.019
Varaprasad B, Srinivasa RC, Vinayac PV (2014) Effect of machining parameters on tool wear in hard turning of AISI D3 steel. Proc Eng 97:338–345. https://doi.org/10.1016/j.proeng.2014.12.257
Deshpande Y, Andhare A, Sahu NK (2017) Estimation of surface roughness using cutting parameters, force, sound, and vibration in turning of Inconel 718. J Braz Soc Mech Sci Eng 39(5):1–10. https://doi.org/10.1007/s40430-017-0819-4
Ferreira R, Rehor J, Lauro CH, Carou D, Davim JP (2016) Analysis of the hard turning of AISI H13 steel with ceramic tools based on tool geometry: surface roughness, tool wear and their relation. J Braz Soc Mech Sci Eng 38(8):2413–2420. https://doi.org/10.1007/s40430-016-0504-z
Sandvik http://www.sandvik.coromant.com/ens/products/Pages/productdetails.aspx?c = cnmg%20433-pf%204325
da Silva RB, Machado AR, Ezugwub EO, Bonneyc J, Sales WF (2013) Tool life and wear mechanisms in high speed machining of Ti–6Al–4V alloy with PCD tools under various coolant pressures. J Mater Process Technol 213(8):1459–1464. https://doi.org/10.1016/j.jmatprotec.2013.03.008
Degarmo EP, Black JT, Kohser RA (2003) Materials and processes in manufacturing, 9th edn. Wiley, New Jersey. ISBN 0-471-65653-4
Acknowledgements
The authors are indebted to University of Taubaté and State University of Campinas, Nove de Julho University, and also to Brazilian Research Council (CNPq) for supporting this work.
Author information
Authors and Affiliations
Corresponding author
Additional information
Technical Editor: Márcio Bacci da Silva.
Rights and permissions
About this article
Cite this article
Coppini, N.L., Diniz, A.E., Lacerda, F.S. et al. Internal turning of sintered carbide parts: tool wear and surface roughness evaluation. J Braz. Soc. Mech. Sci. Eng. 40, 216 (2018). https://doi.org/10.1007/s40430-018-1139-z
Received:
Accepted:
Published:
DOI: https://doi.org/10.1007/s40430-018-1139-z