An experimental investigation was conducted to determine the effects of tool cutting-edge geometry (edge preparation) and workpiece hardness on surface residual stresses for finish hard turning of through-hardened AISI 52100 steel. Polycrystalline cubic boron nitride (PCBN) inserts with representative types of edge geometry including “up-sharp” edges, edge hones, and chamfers were used as the cutting tools in this study. This study shows that tool edge geometry is highly influential with respect to surface residual stresses, which were measured using x-ray diffraction. In general, compressive surface residual stresses in the axial and circumferential directions were generated by large edge hone tools in longitudinal turning operations. Residual stresses in the axial and circumferential directions generated by large edge hone tools are typically more compressive than stresses produced by small edge hone tools. Microstructural analysis shows that thermally-induced phase transformation effects are present at all feeds and workpiece hardness values with the large edge hone tools, and only at high feeds and hardness values with the small edge hone tools. In general, continuous white layers on the workpiece surface correlate with compressive residual stresses, while over-tempered regions correlate with tensile or compressive residual stresses depending on the workpiece hardness. [S1087-1357(00)00304-X]
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November 2000
Technical Papers
Effect of Cutting-Edge Geometry and Workpiece Hardness on Surface Residual Stresses in Finish Hard Turning of AISI 52100 Steel
Jeffrey D. Thiele,
Jeffrey D. Thiele
The George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA 30332-0405
11
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Shreyes N. Melkote,
Shreyes N. Melkote
The George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA 30332-0405
22
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Roberta A. Peascoe,
Roberta A. Peascoe
High Temperature Materials Laboratory, Oak Ridge National Laboratories, Oak Ridge, TN 37831-6064
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Thomas R. Watkins
Thomas R. Watkins
High Temperature Materials Laboratory, Oak Ridge National Laboratories, Oak Ridge, TN 37831-6064
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Jeffrey D. Thiele
11
The George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA 30332-0405
Shreyes N. Melkote
22
The George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA 30332-0405
Roberta A. Peascoe
High Temperature Materials Laboratory, Oak Ridge National Laboratories, Oak Ridge, TN 37831-6064
Thomas R. Watkins
High Temperature Materials Laboratory, Oak Ridge National Laboratories, Oak Ridge, TN 37831-6064
Contributed by the Manufacturing Engineering Division for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received Mar. 1999; revised Dec. 1999. Associate Technical Editor: M. Elbestawi.
J. Manuf. Sci. Eng. Nov 2000, 122(4): 642-649 (8 pages)
Published Online: December 1, 1999
Article history
Received:
March 1, 1999
Revised:
December 1, 1999
Citation
Thiele, J. D., Melkote, S. N., Peascoe , R. A., and Watkins, T. R. (December 1, 1999). "Effect of Cutting-Edge Geometry and Workpiece Hardness on Surface Residual Stresses in Finish Hard Turning of AISI 52100 Steel ." ASME. J. Manuf. Sci. Eng. November 2000; 122(4): 642–649. https://doi.org/10.1115/1.1286369
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