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Hard Part Machining Techniques Explained

This document discusses hard part machining processes. It defines hard part machining as finishing operations on machine parts with a hardness over 60 HRC, which were traditionally done by grinding. However, hard cutting operations using tools with defined cutting edges are now commonly used to replace grinding. Hard cutting with ceramic or CBN tools can reduce costs, decrease production time, improve quality, offer flexibility, and allow dry machining by eliminating coolants. Hard turning can provide high accuracy for many hard parts but can cause problems with surface integrity like residual stresses and white layers that reduce fatigue life.

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13 views1 page

Hard Part Machining Techniques Explained

This document discusses hard part machining processes. It defines hard part machining as finishing operations on machine parts with a hardness over 60 HRC, which were traditionally done by grinding. However, hard cutting operations using tools with defined cutting edges are now commonly used to replace grinding. Hard cutting with ceramic or CBN tools can reduce costs, decrease production time, improve quality, offer flexibility, and allow dry machining by eliminating coolants. Hard turning can provide high accuracy for many hard parts but can cause problems with surface integrity like residual stresses and white layers that reduce fatigue life.

Uploaded by

irinuca12
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

Advanced Machining Processes 245

[22] R.P. Zeilmann, W.L. Weing~irtner, Analysis of temperature during drilling of Ti6A14V with minimal quantity of
lubricant, J. Mater. Proc. Technol., Vol. 179 (2006), 124-127.
[23] A.S. Varadarjan, P.K. Philip, B. Ramamoorthy, Investigations on hard turning with minimal cutting fluid application
(HTMF) and its comparison with dry and wet turning, Int. J. Mach. Tools Manuf., Vol. 42 (2002), 193-200.
[24] W. Zielasko, Chip removal, transport and machine tool cleaning technology, Proceedings of First International Workshop
on High Performance Cutting, Paris, 2002, pp. 53-59.

.-~- 15.3 HARD PART MACHiNiNG


15.3.1 Definition of basic feature of hard part machining (HM)
Traditionally, the finishing operations on the machine parts in a highly tempered or hardened state with
hardness value in excess of 60 H1KC are grinding processes, but recently hard cutting operations using
tools with geometrically defined cutting edges have become more and more capable of replacing t h e m and
guaranteeing comparable surface finish (possible values of 0.1 Ixm Ra in C B N high precision machining) and
IT (tolerance) standards (correspondingly IT3), as shown in Fig. 15.43. Their applications have spread over
such leading industrial branches as automotive, roller bearing, hydraulic and die and moulds sectors. Gear
wheels, geared shafts, bearing tings and other transmission parts are typically machined by turning, while
high speed milling is a leading technology in the die and moulds industry.
In particular, the hard cutting process performed with ceramic or C B N tools can often cut manufacturing
costs, decrease production time (lead-time), improve overall product quality, offer a higher flexibility and
allow dry machining by eliminating coolants (Fig. 15.43b). The two first advantages lead to substantial
shortening of the traditional technological chain with heat treatment and finish grinding after rough operation,
as illustrated in Fig. 15.44.
In general, hard turning can provide a relatively high accuracy for many hard parts but sometimes
important problems arise with surface integrity, especially with undesirable patterns of residual stresses and
the changes of subsurface microstructure, so-called white layer, which reduces fatigue life of turned surfaces.

(a) (b) Low sub-


10 surface damage
I
gm I.................... Environl - nsion
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iiiRo~_~ hard turning racy
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Quality of
rrN Minimum surface
6 setup time
r
ID
roughness
r
r " I
I I
4 - High precision Process
rrO hard turning ::):ii::~i~:i
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trends I ~ ~ specificconditions removal tensile stress
- ~P-"--
rate
0 ..L. 1
0 2 4 0 8 lo 14 - I - Hard cutting
IT (ISO tolerance) -0- Grinding

Fig. 15.43 Achievable surface roughness and ISO tolerance in hard turning (a) [1 ] qualitative comparison of hard
turning and grinding processes [2].

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