1. Stuart McAllister October 10, 2007
“Effect on cutting force in turning hardened tool steels with cubic boron nitride inserts.”
Authors: Mohammad Robiul Hossan & Li Qian
Journal of Materials Processing Technology
Volume 191, Issues 1-3, 1 August 2007, Pages
Stuart McAllister
October 10, 2007

2. Introduction
A performance comparison of turning various hardened steels with CBN inserts is not available in literature.
FEA results in terms of forces are presented for orthogonal high-speed machining of:
AISI hardened bearing steel
AISI H13 hot work tool steel
AISI D2 cold work steel
AISI 4340 low alloy steel

3. Introduction The following effects on forces were investigated:
Cutting speed
Feed
Cutter Geometry
Workpiece hardness
FEA results were compared with the experimental results reported in the referenced literature.

4. Models & Design Principles
AdvantEdge software used:
To perform numerical simulations with FEA
2D Lagrangian FEA modeling software
Models created:
FEA model
Machining process model
Material properties model
Friction model
Detailed information on models in Ref. [10]

5. Models & Design Principles
Fig. 1 shows the schematic of orthogonal cutting conditions used for the 2D finite element mesh.
The cutting tool is characterized by rake angle, relief angle, and cutting edge radius.
The process parameters include feed f, cutting speed V, and depth of cut (doc).
(Fig. 1.) 

6. Models & Design Principles
Table 1. material properties, heat treat process, application
Material
UTS YS E
Heat Treat Process
Application
H13
1990
1650
210
Quench, annealing, stress relieving
Die casting dies
52100
1640
1230
Quenched, harden
Bearings D2
2940
2200
Harden
Gages, long-run dies
4340
1300
1200
Quench, temper
General application

7. Models & Design Principles
Table 2. Cutting process parameters in numerical simulations
Workpiece hardness
44, 48, 52, 58 HRC
Workpiece material
AISI 52100, D2, H13, AISI 4340
Tool insert
CBN
Depth of cut (mm)
0.2
Feed (mm)
0.15, 0.3, 0.45, 0.6
Cutting speed (m/min)
140, 180, 240
Rake angle (°)
−5, −15, −25
Edge radius (mm)
0.02, 0.06, 0.1, 0.2
Relief angle (°) 6

8. Results Data on cutting forces is essential:
For minimizing distortion of machine components, workpiece, fixture, and cutters.
For selecting a machine and machine tool with adequate power.
Forces arising from orthogonal cutting:
Cutting Force – in direction of cutting speed
Feed Force – normal to cutting speed

9. Results
Forces do not change much with cutting speed within the recommended cutting speed range.
Fig. 2. Effect of CS and workpiece material on cutting force.
Fig. 3. Effect of CS and workpiece material on feed force.

10. Results
Feed has the most significant effect on cutting and feed forces.
Forces increase with the increase in feed due to an increase in chip load.
Fig. 4. Effect of feed and material on cutting force.
Fig. 5. Effect of feed and material on feed force.

11. Results Force increase as tool radius increases.
Forces increase as rake angle decreases.
Fig. 7. Effect of rake angle and tool material on cutting force.
Fig. 6. Effect of tool edge radius and tool material on cutting force.

12. Results Force increases as hardness increases.
Forces increase as depth of cut increases.
Fig. 8. Effect of hardness and tool material on cutting force.
Fig. 9. Effect of depth of cut on forces.

13. Conclusions
Predicted cutting forces agree with available literature data with reasonable accuracy.
Cutting force and feed force increase with increasing feed, tool edge radius, negative rake angle, and workpiece hardness.
Feed force is a larger force component than cutting force in hard turning.
Consistent with experimental and numerical results of other researchers.

14. Conclusions Under same turning conditions:
AISI 4340 highest cutting force
AISAS highest feed force
AISI D2 lowest cutting and feed forces
Further work should include:
More experimental runs to verify conclusions
Investigating temperature, shear angle, chip geometry, shear stress, plastic strain rate
Using 3D FEA model simulations

15. Conclusions Industrial Use? Technical Advancement?
A performance comparison of turning hardened steels with CBN inserts now available.
Technical Advancement?
No, but more information on hard turning available.
Industries impacted?
Those that perform hard machining with CBN inserts will have more data available to them.

16. References
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[10] T.D. Marusich, M. Ortiz, Modeling and simulation of high-speed machining, Int. J. Numerical Method Eng. 38 (1995) 3675–3694.