Skip to main content
SpringerLink
Log in

Machining of Hard Materials – Definitions and Industrial Applications

  • Chapter
Book cover Machining of Hard Materials

Abstract

In its broad definition, hard machining is machining of parts with a hardness of above 45 HRC, although most frequently the process concerns hardnesses of 58 to 68 HRC. The workpiece materials involved include various hardened alloy steels, tool steels, case-hardened steels, superalloys, nitrided irons and hard-chromecoated steels, and heat-treated powder metallurgical parts. It is mainly a finishing or semi-finishing process where high dimensional, form, and surface finish accuracy have to be achieved [1].

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

Access this chapter

Log in via an institution
Chapter
USD 29.95
Price excludes VAT (USA)
  • Available as PDF
  • Read on any device
  • Instant download
  • Own it forever
eBook
USD 84.99
Price excludes VAT (USA)
  • Available as EPUB and PDF
  • Read on any device
  • Instant download
  • Own it forever
Softcover Book
USD 109.99
Price excludes VAT (USA)
  • Compact, lightweight edition
  • Dispatched in 3 to 5 business days
  • Free shipping worldwide - see info
Hardcover Book
USD 109.99
Price excludes VAT (USA)
  • Durable hardcover edition
  • Dispatched in 3 to 5 business days
  • Free shipping worldwide - see info

Tax calculation will be finalised at checkout

Purchases are for personal use only

Institutional subscriptions

Notes

  1. 1.

    The property of being hard enough to cut metals even when heated to a dull-red color.

References

  1. Richt C (2009) Hard turn toward efficiency. Gear Solutions (4): 22–30.

    Google Scholar 

  2. Chou YK, Evans CJ (1999) White layers and thermal modeling of hard turned surfaces. International Journal of Machine Tools and Manufacture 39(12): 1863–1881.

    Article  Google Scholar 

  3. Hashimoto F, Guo YB, Warren AW (2006) Surface integrity difference between hard turned and ground surfaces and its impact on fatigue life. CIRP Annals – Manufacturing Technology 55(1): 81–84.

    Article  Google Scholar 

  4. Bosheh SS, Mativenga PT (2006) White layer formation in hard turning of H13 tool steel at high cutting speeds using CBN. International Journal of Machine Tools and Manufacture 46(2): 225–233.

    Article  Google Scholar 

  5. Nakayama K, Arai M, Kanda T (1988) Machining characteristic of hard materials. CIRP Annals – Manufacturing Technology 37: 89–92.

    Article  Google Scholar 

  6. Shaw MC, Vyas A (1993) Chip Formation in the Machining of Hardened Steel. CIRP Annals – Manufacturing Technology 42(1): 29–33.

    Article  Google Scholar 

  7. Tönshoff HK, Wobker HG, Brandt D (1995) Tribological aspects of hard turning with ceramic tools. Journal of Society of Tribologists and Lubrification Engineers 51(2): 163–168.

    Google Scholar 

  8. Tönshoff HK, Arendt C, Ben Amor R (2000) Cutting of hardened steel. CIRP Annals – Manufacturing Technology 49(2): 547–566.

    Article  Google Scholar 

  9. Davies MA, Burns TJ, Evans CJ (1997) On the dynamics of chip formation in machining hard metals. CIRP Annals – Manufacturing Technology 46(1): 25–30.

    Article  Google Scholar 

  10. Elbestawi MA, Srivastawa SAK, El-Wardany TI, (1996) Model for chip formation during machining of hardened steel. CIRP Annals – Manufacturing Technology 45(1): 71–76.

    Article  Google Scholar 

  11. König W, Klinger M, Link R (1990) Machining hard materials with geometrically defined cutting edges. CIRP Annals – Manufacturing Technology 39(1): 61–64.

    Article  Google Scholar 

  12. Atkins AG (2006) Toughness and oblique metalcutting. ASME Journal of Manufacturing Science and Engineering 128: 775–786.

    Article  Google Scholar 

  13. Atkins T (2009) The Science and Engineering of Cutting, Amsterdam: Butterworth-Heinemann.

    Google Scholar 

  14. Atkins AG, Mai YW (1985) Elastic and Plastic Fracture: Metals, Polymers. Ceramics, Composites, Biological Materials, New York: John Wiley & Sons.

    Google Scholar 

  15. Atkins AG (2003) Modelling metal cutting using modern ductile fracture mechanics: qualitative explanations for some longstanding problems. International Journal of Mechanical Science 45: 373–396.

    Article  Google Scholar 

  16. Huang Y, Liang SY (2003) Cutting forces modeling considering the effect of tool thermal property – application to CBN hard turning. International Journal of Machine Tools and Manufacture 43(3): 307–315.

    Article  Google Scholar 

  17. Lalwani DI, Mehta NK, Jain PK (2008) Experimental investigations of cutting parameters influence on cutting forces and surface roughness in finish hard turning of MDN250 steel. Journal of Materials Processing Technology 206(1–3): 167–179.

    Article  Google Scholar 

  18. Remadna M, Rigal JF (2006) Evolution during time of tool wear and cutting forces in the case of hard turning with CBN inserts. Journal of Materials Processing Technology 178(1–3): 67–75.

    Article  Google Scholar 

  19. Astakhov VP (2010) Geometry of Single-Point Turning Tools and Drills. Fundamentals and Practical Applications, London: Springer.

    Book  Google Scholar 

  20. Astakhov VP, Xiao X (2008) A methodology for practical cutting force evaluation based on the energy spent in the cutting system. Machining Science and Technology 12: 325–347.

    Article  Google Scholar 

  21. Astakhov VP, Outeiro JC (2008) Metal cutting mechanics, finite element modeling. In: Davim PJ (ed) Machining fundamentals and recent advances. Springer, London, pp 1–27.

    Google Scholar 

  22. Incopera FP, De Witt DP, (2001) Fundamentals of Heat and Mass Transfer. 5th ed., New York: John Wiley and Sons.

    Google Scholar 

  23. Manca O, Morrone D, Nardini S (1999) Thermal analysis of solids at high peclet numbers subjected to moving heat sources. ASME Journal of Heat Transfer 121–1: 182–186.

    Article  Google Scholar 

  24. Muzychka YS, Yovanovich MM (2001) Thermal resistance models for non-circular moving heat sources on a half space. Journal of Heat Transfer 123(4): 624–632.

    Article  Google Scholar 

  25. Ostafiev VA, Noshchenko AN (1985) Numerical analysis of three-dimensional heat exchange in oblique cutting. CIRP Annals-Manufacturing Technology 34(1): 137–140.

    Article  Google Scholar 

  26. Astakhov VP (1998/1999) Metal Cutting Mechanics, Boca Raton, USA: CRC Press.

    Google Scholar 

  27. Astakhov VP, Shvets S (2004) The assessment of plastic deformation in metal cutting. Journal of Materials Processing Technology 146: 193–202.

    Article  Google Scholar 

  28. Astakhov VP, Shvets SV (2001) A novel approach to operating force evaluation in high strain rate metal-deforming technological processes. Journal of Materials Processing Technology 117(1–2): 226–237.

    Article  Google Scholar 

  29. Astakhov VP (2006) Tribology of Metal Cutting. Triblogy and Interface Engineering Series, No. 52, ed. B.J. Briscoe, London: Elsevier.

    Google Scholar 

  30. Poulachon G, Moisan A, Jawahir IS (2001) On modelling the influence of thermo-mechanical behavior in chip formation during hard turning of 100Cr6 bearing steel. CIRP Annals – Manufacturing Technology 50(1): 31–36.

    Article  Google Scholar 

  31. Silin SS (1979) Similarity Methods in Metal Cutting (in Russian). Mashinostroenie, Moscow.

    Google Scholar 

  32. Dumitrescu PK, Koshy P, Stenekes J, Elbestawi MA (2006) High-power diode laser assisted hard turning of AISI D2 tool steel. International Journal of Machine Tools and Manufacture 46(15): 2009–2016.

    Article  Google Scholar 

  33. Ludema KC (1996) Friction, Wear, and Lubrication – a Textbook in Tribology, Boca Raton (Florida): CRC Press.

    Book  Google Scholar 

  34. Grzesik G (2008) Machining of hard materials, in Machining: Fundamentals and Recent Advances, P. Davim, Editor, Springer: London. p. 97–126.

    Google Scholar 

  35. Zurek G (2004) The secrets to hard milling success. Moldmaking Technology (4): 14–18.

    Google Scholar 

  36. Astakhov VP (2004) The assessment of cutting tool wear. International Journal of Machine Tools and Manufacture 44: 637–647.

    Article  Google Scholar 

  37. Makarov VF, Tokarev DI, Tyktamishev VR (2008) High speed broaching of hard machining materials. International Journal of Material Forming 1(1): 547–550.

    Article  Google Scholar 

  38. Klocke, F., Brinksmeier, E. and Weinert, K. (2005) Capability profile of hard cutting and grinding processes. CIRP Annals-Manufacturing Technology 54(2): 552–580.

    Article  Google Scholar 

  39. Klimenko SA, Manokhin AS (2009) Hard “skiving” turning. Journal of Superhard Materials 31(1): 42–54.

    Article  Google Scholar 

  40. Grzesik W, Rech J, Wanata T (2007) Surface finish on hardened bearing steel parts produced by superhard and abrasive tools. Int. J. Machine Tools & Manufacture 47: 255–262.

    Article  Google Scholar 

  41. Klimenko SA (1998) Special features of machining protective coatings. Journal of Superhard Materials 20(3): 440–445.

    Google Scholar 

  42. Astakhov VP (2010) Geometry of Single-Point Turning Tools and Drills. Fundamentals and Practical Applications, London: Springer.

    Book  Google Scholar 

  43. Astakhov VP, Davim PJ (2008) Tools (geometry and material) and tool wear. In: Davim PJ (ed) Machining: fundamentals and recent advances. Springer, London, pp 29–58.

    Google Scholar 

  44. Antoniadis A, Vidakis N, Bilalis N (2004) A simulation model of gear skiving. Journal of Materials Processing Technology 146: 213–220.

    Article  Google Scholar 

  45. Gimpert D (1991) Fine pitch gear hobbing advances. SME Technical Paper MS91-246.

    Google Scholar 

  46. Shaw MC (2004) Metal Cutting Principles. 2nd Edition, Oxford: Oxford University Press.

    Google Scholar 

  47. Dessoly V, Melkote SN, Lescalier C (2004) Modeling and verification of cutting tool temperatures in rotary tool turning of hardened steel. International Journal of Machine Tools and Manufacture 44(14): 1463–1470.

    Article  Google Scholar 

  48. Diniz AE, Ferreira JR, Filho FT (2003) Influence of refrigeration/lubrication condition on SAE 52100 hardened steel turning at several cutting speeds. International Journal of Machine Tools and Manufacture 43(3): 317–326.

    Article  Google Scholar 

  49. Kishawy HA, Wilcox J (2003) Tool wear and chip formation during hard turning with self-propelled rotary tools. International Journal of Machine Tools and Manufacture 43(3): 433–439.

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Michigan State University, 2453 Engineering Building, 48824-1226, East Lansing, MI, USA

    Viktor P. Astakhov

Authors
  1. Viktor P. Astakhov
    View author publications

    You can also search for this author in PubMed Google Scholar

Editor information

Editors and Affiliations

  1. Department of Mechanical Engineering, University of Aveiro, Campus Universitário de Santiago, 3810-193, Aveiro, Portugal

    J. Paulo Davim

Rights and permissions

Reprints and permissions

Copyright information

© 2011 Springer-Verlag London Limited

About this chapter

Cite this chapter

Astakhov, V. (2011). Machining of Hard Materials – Definitions and Industrial Applications. In: Davim, J. (eds) Machining of Hard Materials. Springer, London. https://doi.org/10.1007/978-1-84996-450-0_1

Download citation

  • DOI: https://doi.org/10.1007/978-1-84996-450-0_1

  • Publisher Name: Springer, London

  • Print ISBN: 978-1-84996-449-4

  • Online ISBN: 978-1-84996-450-0

  • eBook Packages: EngineeringEngineering (R0)

Publish with us

Policies and ethics

Search

Navigation