Mechanism and kinetics of pcbn tool wear during face milling of hardened steel
| Назва | Mechanism and kinetics of pcbn tool wear during face milling of hardened steel |
| Назва англійською | Mechanism and kinetics of pcbn tool wear during face milling of hardened steel |
| Автори | Yana Kovalenko |
| Принадлежність | Zhytomyr Polytechnic State University, Zhytomyr, Ukraine |
| Бібліографічний опис | Mechanism and kinetics of pcbn tool wear during face milling of hardened steel / Yana Kovalenko // Scientific Journal of TNTU. — Tern.: TNTU, 2025. — Vol 117. — No 1. — P. 87–97. |
| Bibliographic description: | Kovalenko Y. (2025) Mechanism and kinetics of pcbn tool wear during face milling of hardened steel. Scientific Journal of TNTU (Tern.), vol 117, no 1, pp. 87–97. |
| DOI: | https://doi.org/10.33108/visnyk_tntu2025.01.087 |
| УДК | 621.91 |
| Ключові слова | hardened steel, face milling, wear mechanism, diffusion wear, cubic boron nitride, BL and BH groups. |
This article presents the results of a study on the wear behavior of cutting tools equipped with polycrystalline cubic boron nitride (PCBN) inserts in the machining of 4Kh5MFS hardened steel with a high hardness of 62 HRC. A key property of 4Kh5MFS steel is its ability to be hardened uniformly without losing hardness throughout the depth of the workpiece, and to maintain its strength level under high temperatures and mechanical loading. Laboratory experiments were carried out on vertical milling machines – DMU 80 eVo Deckel Maho and HAAS VF-2SSYT-NG – using a Seco Tools face mill with a built-in inclination angle of −6°, fitted with six cutting inserts at negative angles of −20° and −25°. Four types of Seco Tools inserts were employed: Group BH (CBN200, CH3505, DBS900) and Group BL (DCS500). The study focuses on comparing the performance of PCBN tools in BL and BH groups, which differ in composition, microstructure, and resistance to shock and high temperatures. Group BH inserts exhibit higher fracture toughness and strength, making them generally recommended for operations involving considerable dynamic loading. The wear rate of PCBN tools, especially at high cutting speeds, is largely determined by the mechanical, chemical, and adhesive interactions in the cutting zone, driven by tribological reactions between the cutting and workpiece materials. By means of energy-dispersive X-ray (EDX) microscopy, the worn areas of the cutting inserts were scanned to identify the wear mechanism, measure the width of the worn notch, and detect any chemical element adhesion that occurred as a result of interactions between the workpiece and the cutting insert over time. Based on the research findings and subsequent analysis, characteristic wear stages for each PCBN tool group were established, along with recommended cutting conditions that provide the best balance between machining efficiency and tool life. The practical significance of this study lies in the development of guidelines for selecting the appropriate type of PCBN tool (BL or BH) depending on thermal and mechanical loading conditions and the required surface quality. | |
| ISSN: | 2522-4433 |
| Перелік літератури |
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2. Zhiyu Z., Peng H., and Yan J., (2013) “Micro-cutting characteristics of EDM fabricated high-precision polycrystalline diamond tools,” Int. J. of Machine Tools and Manufacture, vol. 65, pp. 99–106.
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7. Wojciechowski S. and Twardowski P. (2012) “Tool life and process dynamics in high speed ball end milling of hardened steel”. Procedia Cirp, vol. 1, pp. 289–294.
8. Gopalsamy B. M., Mondal B., Ghosh S., Arntz K., and Klocke F. (2009) “Investigations on hard machining of Impax Hi Hard tool steel”. Int. J. of Material Forming, vol. 2, no. 3, pp. 145–165.
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10. Fujisaki K. et al, (2009) “Development of ultra-fine-grain binderless cBN tool for precision cutting of ferrous materials”. J. of Materials Processing Technology, vol. 209, no. 15, pp. 5646–5652.
11. Naganuma K. and Mori M. (2012) “High Precise Milling Process by cBN End Mills”. Int. J. of Automation Technology, vol. 6, no. 4, pp. 542–545.
12. Hirosaki K., Shintani K., Kato H., Asakura F., and Matsuo K. (2004) “High speed machining of bio-titanium alloy with a binder-less PcBN tool”. JSME Int. J. Series C Mechanical Systems, Machine Elements and Manufacturing, vol. 47, no. 1, pp. 14–20.
13. Mustafizur R., Wang Z., and Wong Y. (2006) “A review on high-speed machining of titanium alloys”. JSME Int. J. Series C, vol. 49, no. 1, pp. 11–20.
14. Hamaguchi K., Hirayama A., Shizuka H., and Okuda K. (2012) “Effect of Run-Out on Tool Wear Characteristics and Cutting Forces in Micro Ball End Mill”. Trans. of Japan Society of Mechanical Engineers Series C, vol. 78, no. 791, pp. 2689–2697.
15. Bao W. Y., and Tansel I. N. (2000) “Modeling micro-end-milling operations. Part II: tool run-out”. Int. J. of Machine Tools and Manufacture, vol. 40, no. 15, pp. 2175–2192.
16. Masuda M., Nogami T., Mizobuchi A., and Nagahama T (2000) “The Behavior of Tool Life and Cutting Temperature on High Speed Milling of Hardened Alloy Tool Steels”. J. of the Japan Society for Precision Engineering, vol. 66, no. 11, pp. 1745–1749.
17. Tanaka H., Sugihara T., & Enomoto T. (2016) High Speed Machining of Inconel 718 Focusing on Wear Behaviors of PCBN Cutting Tool. Procedia CIRP, no. 46, pp. 545–548.
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| References: |
1. Sugano T., Takeuchi K., Goto T., Yoshida Y., and Ikawa N., (1987) “Diamond turning of an aluminum alloy for mirror”. CIRP Annals-Manufacturing Technology, vol. 36, no. 1, pp. 17–20.
2. Zhiyu Z., Peng H., and Yan J., (2013) “Micro-cutting characteristics of EDM fabricated high-precision polycrystalline diamond tools,” Int. J. of Machine Tools and Manufacture, vol. 65, pp. 99–106.
3. Nakamoto K., Aoyama T., Katahira K., Fonda P., and Yamazaki K., (2012) “A study of nanometric surface generation on tungsten carbide using a micro polycrystalline diamond end mill,” Int. J. of Automation Technology, vol. 6, no. 4, pp. 547–553,.
4. Takeuchi Y., Sawada K., and Sata T. (1997) “Manufacture of Micropropellers byMeans of Ultraprecision Milling Machine” . J. of Robotics and Mechatronics, vol. 9, no. 6, pp. 475–479.
5. Iwabe H. and Enta K. (2008) “Tool Life of Small Diameter Ball End Mill for High Speed Milling of Hardened Steel”. Int. J. of Automation Technology, vol. 2, no. 6, pp. 425–430.
6. Gopalsamy B. M., Mondal B., Ghosh S., Arntz K., and Klocke F., (2010) “Experimental investigations while hard machining of DIEVAR tool steel (50 HRC)”. The Int. Journal of Advanced Manufacturing Technology, vol. 51, no. 9, pp. 853–869.
7. Wojciechowski S. and Twardowski P. (2012) “Tool life and process dynamics in high speed ball end milling of hardened steel”. Procedia Cirp, vol. 1, pp. 289–294.
8. Gopalsamy B. M., Mondal B., Ghosh S., Arntz K., and Klocke F. (2009) “Investigations on hard machining of Impax Hi Hard tool steel”. Int. J. of Material Forming, vol. 2, no. 3, pp. 145–165.
9. Becze C. E., Clayton P., Chen L., El-Wardany T. I., and Elbestawi M. A. (2000) “High-speed five-axis milling of hardened tool steel”. Int. J. of Machine Tools and Manufacture, vol. 40, no. 6, pp. 869–885.
10. Fujisaki K. et al, (2009) “Development of ultra-fine-grain binderless cBN tool for precision cutting of ferrous materials”. J. of Materials Processing Technology, vol. 209, no. 15, pp. 5646–5652.
11. Naganuma K. and Mori M. (2012) “High Precise Milling Process by cBN End Mills”. Int. J. of Automation Technology, vol. 6, no. 4, pp. 542–545.
12. Hirosaki K., Shintani K., Kato H., Asakura F., and Matsuo K. (2004) “High speed machining of bio-titanium alloy with a binder-less PcBN tool”. JSME Int. J. Series C Mechanical Systems, Machine Elements and Manufacturing, vol. 47, no. 1, pp. 14–20.
13. Mustafizur R., Wang Z., and Wong Y. (2006) “A review on high-speed machining of titanium alloys”. JSME Int. J. Series C, vol. 49, no. 1, pp. 11–20.
14. Hamaguchi K., Hirayama A., Shizuka H., and Okuda K. (2012) “Effect of Run-Out on Tool Wear Characteristics and Cutting Forces in Micro Ball End Mill”. Trans. of Japan Society of Mechanical Engineers Series C, vol. 78, no. 791, pp. 2689–2697.
15. Bao W. Y., and Tansel I. N. (2000) “Modeling micro-end-milling operations. Part II: tool run-out”. Int. J. of Machine Tools and Manufacture, vol. 40, no. 15, pp. 2175–2192.
16. Masuda M., Nogami T., Mizobuchi A., and Nagahama T (2000) “The Behavior of Tool Life and Cutting Temperature on High Speed Milling of Hardened Alloy Tool Steels”. J. of the Japan Society for Precision Engineering, vol. 66, no. 11, pp. 1745–1749.
17. Tanaka H., Sugihara T., & Enomoto T. (2016) High Speed Machining of Inconel 718 Focusing on Wear Behaviors of PCBN Cutting Tool. Procedia CIRP, no. 46, pp. 545–548.
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