Modeling in preheated machining of AISI D2 hardened steel

Tool life prediction plays an important role in modern industry for sustainable manufacturing and product design. The productivity of a machining system and machining cost, as well as quality and integrity of the machined surface strongly depend on tool wear and tool life. Sudden failure of cutti...

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Main Authors:	Lajis, M. A., Amin, A. K. M. Nurul, Karim, A.N. Mustafizul, Ginta, Turnad Lenggo
Format:	Book Chapter
Language:	English
Published:	IIUM Press 2011
Subjects:	TJ Mechanical engineering and machinery
Online Access:	http://irep.iium.edu.my/23585/ http://irep.iium.edu.my/23585/ http://irep.iium.edu.my/23585/4/chp6.pdf

id	iium-23585
recordtype	eprints
spelling	iium-235852012-09-05T03:04:27Z http://irep.iium.edu.my/23585/ Modeling in preheated machining of AISI D2 hardened steel Lajis, M. A. Amin, A. K. M. Nurul Karim, A.N. Mustafizul Ginta, Turnad Lenggo TJ Mechanical engineering and machinery Tool life prediction plays an important role in modern industry for sustainable manufacturing and product design. The productivity of a machining system and machining cost, as well as quality and integrity of the machined surface strongly depend on tool wear and tool life. Sudden failure of cutting tools leads to loss of productivity, rejection of parts and consequential economic losses [1]. The advent of several advanced difficult-to-cut materials such as the heat resistant tool steels has posed a great challenge in their machining. During the last few decades numerous studies have been conducted to improve the machinability of these materials and many large organizations have invested considerably in exploring and developing new techniques to minimize machining costs of these materials while maintaining their quality requirements. The benefits for the manufacture of components from hardened steel are substantial in terms of reduced machining costs and lead times, in comparison with the more traditional route which involves machining in the annealed state, heat treatment, grinding or electrical discharge machining (EDM), and manual finishing [2]. Recent advances in cutting tool and machine tool technologies have opened up new opportunities for investigation in machining hard materials and especially for bulk removal of material. Preheating of workpiece by induction heating has been recently reported to enhance the machinability of materials. The latest work done by Amin et al [3] were carried out with induction heating in end milling of AISI D2 hardened steel using Poly Crystalline Cubic Boron Nitride (PCBN) inserts. They observed that preheated machining of the material leads to surface roughness values well below 0.4 μm, such that the operations of grinding as well as polishing can be avoided at the higher cutting speeds. They added that preheated machining was able to reduce the amplitude of the lower frequency mode of chatter by almost 4.5 times at the cutting speed of 50 m/min. It was also established by several earlier studies [4-7] that preheating had great potential in lowering chatter. The primary causes of this stable cutting need to be studied in the perspective of material properties and damping capability of the material in the preheated condition. The primary objective of preheating is to enhance the ductility of the material for easier chip formation and better chip flow over the rake surface of the tool. In addition preheating is expected to improve the tool life and improve surface finish of the machined components. But preheating may lead to softening of the hardened workpiece. In the earlier study by Amin, et al [3], preheating temperature was in between 100-150 °C and this might not substantially change the hardness of the material. Hence, in the present study an attempt has been made to carry out an investigation in hot machining of end milling operation of AISI D2 hardened steel using induction heating. To discern differences in machinability, the test workpieces were machined with higher range of temperature from 250-450 °C. IIUM Press 2011 Book Chapter PeerReviewed application/pdf en http://irep.iium.edu.my/23585/4/chp6.pdf Lajis, M. A. and Amin, A. K. M. Nurul and Karim, A.N. Mustafizul and Ginta, Turnad Lenggo (2011) Modeling in preheated machining of AISI D2 hardened steel. In: Advanced Machining Towards Improved Machinability of Difficult-to-Cut Materials. IIUM Press, Kuala Lumpur, Malaysia, pp. 43-48. ISBN 9789674181758 http://rms.research.iium.edu.my/bookstore/default.aspx
repository_type	Digital Repository
institution_category	Local University
institution	International Islamic University Malaysia
building	IIUM Repository
collection	Online Access
language	English
topic	TJ Mechanical engineering and machinery
spellingShingle	TJ Mechanical engineering and machinery Lajis, M. A. Amin, A. K. M. Nurul Karim, A.N. Mustafizul Ginta, Turnad Lenggo Modeling in preheated machining of AISI D2 hardened steel
description	Tool life prediction plays an important role in modern industry for sustainable manufacturing and product design. The productivity of a machining system and machining cost, as well as quality and integrity of the machined surface strongly depend on tool wear and tool life. Sudden failure of cutting tools leads to loss of productivity, rejection of parts and consequential economic losses [1]. The advent of several advanced difficult-to-cut materials such as the heat resistant tool steels has posed a great challenge in their machining. During the last few decades numerous studies have been conducted to improve the machinability of these materials and many large organizations have invested considerably in exploring and developing new techniques to minimize machining costs of these materials while maintaining their quality requirements. The benefits for the manufacture of components from hardened steel are substantial in terms of reduced machining costs and lead times, in comparison with the more traditional route which involves machining in the annealed state, heat treatment, grinding or electrical discharge machining (EDM), and manual finishing [2]. Recent advances in cutting tool and machine tool technologies have opened up new opportunities for investigation in machining hard materials and especially for bulk removal of material. Preheating of workpiece by induction heating has been recently reported to enhance the machinability of materials. The latest work done by Amin et al [3] were carried out with induction heating in end milling of AISI D2 hardened steel using Poly Crystalline Cubic Boron Nitride (PCBN) inserts. They observed that preheated machining of the material leads to surface roughness values well below 0.4 μm, such that the operations of grinding as well as polishing can be avoided at the higher cutting speeds. They added that preheated machining was able to reduce the amplitude of the lower frequency mode of chatter by almost 4.5 times at the cutting speed of 50 m/min. It was also established by several earlier studies [4-7] that preheating had great potential in lowering chatter. The primary causes of this stable cutting need to be studied in the perspective of material properties and damping capability of the material in the preheated condition. The primary objective of preheating is to enhance the ductility of the material for easier chip formation and better chip flow over the rake surface of the tool. In addition preheating is expected to improve the tool life and improve surface finish of the machined components. But preheating may lead to softening of the hardened workpiece. In the earlier study by Amin, et al [3], preheating temperature was in between 100-150 °C and this might not substantially change the hardness of the material. Hence, in the present study an attempt has been made to carry out an investigation in hot machining of end milling operation of AISI D2 hardened steel using induction heating. To discern differences in machinability, the test workpieces were machined with higher range of temperature from 250-450 °C.
format	Book Chapter
author	Lajis, M. A. Amin, A. K. M. Nurul Karim, A.N. Mustafizul Ginta, Turnad Lenggo
author_facet	Lajis, M. A. Amin, A. K. M. Nurul Karim, A.N. Mustafizul Ginta, Turnad Lenggo
author_sort	Lajis, M. A.
title	Modeling in preheated machining of AISI D2 hardened steel
title_short	Modeling in preheated machining of AISI D2 hardened steel
title_full	Modeling in preheated machining of AISI D2 hardened steel
title_fullStr	Modeling in preheated machining of AISI D2 hardened steel
title_full_unstemmed	Modeling in preheated machining of AISI D2 hardened steel
title_sort	modeling in preheated machining of aisi d2 hardened steel
publisher	IIUM Press
publishDate	2011
url	http://irep.iium.edu.my/23585/ http://irep.iium.edu.my/23585/ http://irep.iium.edu.my/23585/4/chp6.pdf
first_indexed	2023-09-18T20:35:37Z
last_indexed	2023-09-18T20:35:37Z
_version_	1777409025951924224

Modeling in preheated machining of AISI D2 hardened steel

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