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The Effect of Mechanical Properties and the Cutting Parameters on Machinability of AISI 5140 Steel Cooled at High Cooling Rates After Hot Forging

Year 2019, Volume: 22 Issue: 4, 879 - 887, 01.12.2019
https://doi.org/10.2339/politeknik.479345

Abstract

In this study, the effect of mechanical properties and cutting
parameters (Cp) on the machinability of AISI 5140 steel cooled at high cooling
rates after hot forging was investigated. The microstructural examinations and
hardness measurements of the as-received AISI 5140 steel and the workpieces
cooled in the oil and polymerized water after hot forging were performed. Turning
process was conducted by using a coated ceramic tool at five different cutting
speeds (Vc) (120, 150, 180, 210, and 240 m/min), four different feed rates (fn)
(0.04, 0.08, 0.12, and 0.16 mm/rev), and four different depths of cut (ap)
(0.4, 0.6, 0.8, and 1 mm) under dry machining conditions. SEM examinations of
the cutting tools were also performed. It was seen from the results that the
changing microstructure and hardness values had a significant effect on cutting
forces (Fc) and surface roughness (Ra) from the Cp depending on cooling rate.
While the highest Fc were reached in the workpiece with the highest hardness
cooled in
the polymerized water after hot forging,
the lowest surface roughness (Ra) was obtained in the same workpiece.

References

  • [1] Hu C.L., Zhao Z., Gong A.J., Shi W.B., “Effect of Warm Deformation Parameters and Cooling Rates on the Recrystallization Transformation Microstructure in 40Cr Steel”, Journal of Materials Engineering and Performance, 24: 505-516, (2015). [2] Ceschini L., Marconi A., Martini C., Morr A., Schino A., “Tensile and Impact Behaviour of A Microalloyed Medium Carbon Steel: Effect of The Cooling Condition and Corresponding Microstructure”, Materials & Design, 45: 171-178, (2013).[3] Ulas H.B., Bilgin M., Sezer M.B., Özkan M.T., Performance of Coated and Uncoated Carbide/Cermet Cutting Tools During Turning”, Materials Testing 60: 893-901, (2018).[4] Shalaby M.A., El Hakim M.A., Abdelhameed M.M., Krzanowski J.E., Veldhuis S.C. Dosbaevad G.K., “Wear Mechanisms of Several Cutting Tool Materials in Hard Turning of High Carbon-Chromium Tool Steel”, Tribology International, 70: 148-154, (2014).[5] Tang L., Cheng Z., Huang J., Gao C., Chang W., “Empirical Models For Cutting Forces in Finish Dry Hard Turning of Hardened Tool Steel at Different Hardness Levels”, The International Journal of Advanced Manufacturing Technology, 76:691-703, (2015).[6] Bartarya G., Choudhury S.K., “State of The Art in Hard Turning”, International Journal of Machine Tools and Manufacture, 53: 1-14, (2012).[7] Meddour I., Yallese M.A., Khattabi R., Elbah M., Boulanouar L., “Investigation and Modeling of Cutting Forces and Surface Roughness When Hard Turning of AISI 52100 Steel With Mixed Ceramic Tool: Cutting Conditions Optimization”, The International Journal of Advanced Manufacturing Technology, 77: 1387-1399, (2015).[8] Bouacha K., Yallese M.A., Mabrouki T., Rigal J.F., “Statistical Analysis of Surface Roughness and Cutting Forces Using Response Surface Methodology in Hard Turning of AISI 52100 Bearing Steel With CBN Tool”, International Journal of Refractory Metals and Hard Materials, 28: 349-361, (2010).[9] Grzesik W., Wanat T., “Comparative Assessment of Surface Roughness Produced by Hard Machining With Mixed Ceramic Tools Including 2D and 3D Analysis”, Journal of Materials Processing Technology, 169: 364-371, (2005).[10] Oliveira A.J., Diniz A.E., Ursolino D.J., “Hard Turning in Continuous and İnterrupted Cut With PCBN and Whisker-Reinforced Cutting Tools”, Journal of Materials Processing Technology, 209: 5262-5270, (2009).[11] Aouici H., Yallese M.A., Chaoui K., Mabrouki T., Rigal J.F., “Analysis of Surface Roughness and Cutting Force Components in Hard Turning With CBN Tool: Prediction Model and Cutting Conditions Optimization”, Measurement, 45: 344-353, (2012).[12] Mandal N., Doloi B., Mondal B., Das R., “Optimization of Flank Wear Using Zirconia Toughened Alumina (ZTA) Cutting Tool: Taguchi Method And Regression Analysis”, Measurement, 44: 2149-2155, (2011). [13] Özel T., Hsu T.K., Zeren E., “Effects of Cutting Edge Geometry, Workpiece Hardness, Feed Rate and Cutting Speed on Surface Roughness and Forces in Finish Turning of Hardened AISI H13 Steel”, The International Journal of Advanced Manufacturing Technology, 25: 262-269, (2005).[14] Çalıgülü U., Aras M., Türkmen M., “Effect of Tempering on Microstructure and Hardness Properties of Oil Quenched Steel”, 4th International Symposium on Innovative Technologies in Engineering and Science, Alanya/Antalya-Turkey, 600-607, (2016).[15] Kaynar A., Gündüz S., Türkmen S., “Investigation on the behaviour of medium carbon and vanadium microalloyed steels by hot forging test”, Materials and Design, 51: 819:825, (2013). [16] Selvaraj D.P., Chandramohan P., Mohanraj M., “Optimization of Surface Roughness, Cutting Force and Tool Wear of Nitrogen Alloyed Duplex Stainless Steel in A Dry Turning Process Using Taguchi Method”, Measurement, 49: 205-215, (2014).[17] Thakur D.G., Ramamoorthy B., Vijayaraghavan L., “Study on The Machinability Characteristics of Superalloy Inconel 718 During High Speed Turning”, Materials & Design, 30: 1718-1725, (2009).[18] Yallese A.M., Chaoui K., Zeghibb N., Boulanouar L., Rigal J.F., “Hard Machining of Hardened Bearing Steel Using Cubic Boron Nitride Tool”, Journal of Materials Processing Technology, 209: 1092-1104, (2009).[19] Lima J.G., Avila R.F., Abrao A.M., Faustino M., Davimb J. P., “Hard Turning: AISI 4340 High Strength Low Alloy Steel and AISI D2 Cold Work Tool Steel”, Journal of Materials Processing Technology, 169: 388-395, (2005).[20] Bouchelaghem H., Yallese M.A., Mabrouki T., Amirat A., Rigal J.F., “Experimental Investigation and Performance Analyses of CBN Insert in Hard Turning of Cold Work Tool Steel (D3)”, Machining Science and Technology, 14: 471-501, (2010).[21] Suresh R, Basavarajappa S., Samuel G.L., “Some Studies on Hard Turning of AISI 4340 Steel Using Multilayer Coated Carbide Tool”, Measurement, 45: 1872-1884, (2012).[22] Çiçek A., Kara F., Kıvak T., Ekici E., “Evaluation of Machinability of Hardened and Cryo-Treated AISI H13 Hot Work Tool Steel With Ceramic Inserts”, International Journal of Refractory Metals and Hard Materials, 41: 461-469, (2013).[23] Li S., Xie Y., Wu X., “Hardness and Toughness İnvestigations of Deep Cryogenic Treated Cold Work Die Steel”, Cryogenics, 50: 89-92, (2010). [24] Ferreira R., Carou D., Lauro C.H., Davim J.P., “Surface Roughness Investigation in the Hard Turning of Steel Using Ceramic Tools”, Materials and Manufacturing Processes, 31: 648-652, (2016).[25] Palanisamy D., Senthil P.b, “A Comparative Study on Machinability of Cryo-Treated and Peak Aged 15Cr5Ni Precipitation Hardened Stainless Steel”, Measurement, 116: 162-169, (2018).[26] Lıu K., Shan Y., Yang Z., Lıangj., Lu L., Yang K., “Effect of Heat Treatment on Prior Grain Size and Mechanical Property of a Maraging Stainless Steel”, Journal of Materials Science & Technology, 22:769-774, (2006).[27] Ulaş H.B., “Experimental Determination of Cutting Forces and Surface Roughness when Turning 50CrV4 Steel (SAE 6150) and Modelling with the Artificial Neural Network Approach”, Transactions of the Indian Institute of Metals, 67: 867-879, (2014).

The Effect of Mechanical Properties and the Cutting Parameters on Machinability of AISI 5140 Steel Cooled at High Cooling Rates After Hot Forging

Year 2019, Volume: 22 Issue: 4, 879 - 887, 01.12.2019
https://doi.org/10.2339/politeknik.479345

Abstract

In this study, the effect of mechanical properties and cutting
parameters (Cp) on the machinability of AISI 5140 steel cooled at high cooling
rates after hot forging was investigated. The microstructural examinations and
hardness measurements of the as-received AISI 5140 steel and the workpieces
cooled in the oil and polymerized water after hot forging were performed. Turning
process was conducted by using a coated ceramic tool at five different cutting
speeds (Vc) (120, 150, 180, 210, and 240 m/min), four different feed rates (fn)
(0.04, 0.08, 0.12, and 0.16 mm/rev), and four different depths of cut (ap)
(0.4, 0.6, 0.8, and 1 mm) under dry machining conditions. SEM examinations of
the cutting tools were also performed. It was seen from the results that the
changing microstructure and hardness values had a significant effect on cutting
forces (Fc) and surface roughness (Ra) from the Cp depending on cooling rate.
While the highest Fc were reached in the workpiece with the highest hardness
cooled in
the polymerized water after hot forging,
the lowest surface roughness (Ra) was obtained in the same workpiece.

References

  • [1] Hu C.L., Zhao Z., Gong A.J., Shi W.B., “Effect of Warm Deformation Parameters and Cooling Rates on the Recrystallization Transformation Microstructure in 40Cr Steel”, Journal of Materials Engineering and Performance, 24: 505-516, (2015). [2] Ceschini L., Marconi A., Martini C., Morr A., Schino A., “Tensile and Impact Behaviour of A Microalloyed Medium Carbon Steel: Effect of The Cooling Condition and Corresponding Microstructure”, Materials & Design, 45: 171-178, (2013).[3] Ulas H.B., Bilgin M., Sezer M.B., Özkan M.T., Performance of Coated and Uncoated Carbide/Cermet Cutting Tools During Turning”, Materials Testing 60: 893-901, (2018).[4] Shalaby M.A., El Hakim M.A., Abdelhameed M.M., Krzanowski J.E., Veldhuis S.C. Dosbaevad G.K., “Wear Mechanisms of Several Cutting Tool Materials in Hard Turning of High Carbon-Chromium Tool Steel”, Tribology International, 70: 148-154, (2014).[5] Tang L., Cheng Z., Huang J., Gao C., Chang W., “Empirical Models For Cutting Forces in Finish Dry Hard Turning of Hardened Tool Steel at Different Hardness Levels”, The International Journal of Advanced Manufacturing Technology, 76:691-703, (2015).[6] Bartarya G., Choudhury S.K., “State of The Art in Hard Turning”, International Journal of Machine Tools and Manufacture, 53: 1-14, (2012).[7] Meddour I., Yallese M.A., Khattabi R., Elbah M., Boulanouar L., “Investigation and Modeling of Cutting Forces and Surface Roughness When Hard Turning of AISI 52100 Steel With Mixed Ceramic Tool: Cutting Conditions Optimization”, The International Journal of Advanced Manufacturing Technology, 77: 1387-1399, (2015).[8] Bouacha K., Yallese M.A., Mabrouki T., Rigal J.F., “Statistical Analysis of Surface Roughness and Cutting Forces Using Response Surface Methodology in Hard Turning of AISI 52100 Bearing Steel With CBN Tool”, International Journal of Refractory Metals and Hard Materials, 28: 349-361, (2010).[9] Grzesik W., Wanat T., “Comparative Assessment of Surface Roughness Produced by Hard Machining With Mixed Ceramic Tools Including 2D and 3D Analysis”, Journal of Materials Processing Technology, 169: 364-371, (2005).[10] Oliveira A.J., Diniz A.E., Ursolino D.J., “Hard Turning in Continuous and İnterrupted Cut With PCBN and Whisker-Reinforced Cutting Tools”, Journal of Materials Processing Technology, 209: 5262-5270, (2009).[11] Aouici H., Yallese M.A., Chaoui K., Mabrouki T., Rigal J.F., “Analysis of Surface Roughness and Cutting Force Components in Hard Turning With CBN Tool: Prediction Model and Cutting Conditions Optimization”, Measurement, 45: 344-353, (2012).[12] Mandal N., Doloi B., Mondal B., Das R., “Optimization of Flank Wear Using Zirconia Toughened Alumina (ZTA) Cutting Tool: Taguchi Method And Regression Analysis”, Measurement, 44: 2149-2155, (2011). [13] Özel T., Hsu T.K., Zeren E., “Effects of Cutting Edge Geometry, Workpiece Hardness, Feed Rate and Cutting Speed on Surface Roughness and Forces in Finish Turning of Hardened AISI H13 Steel”, The International Journal of Advanced Manufacturing Technology, 25: 262-269, (2005).[14] Çalıgülü U., Aras M., Türkmen M., “Effect of Tempering on Microstructure and Hardness Properties of Oil Quenched Steel”, 4th International Symposium on Innovative Technologies in Engineering and Science, Alanya/Antalya-Turkey, 600-607, (2016).[15] Kaynar A., Gündüz S., Türkmen S., “Investigation on the behaviour of medium carbon and vanadium microalloyed steels by hot forging test”, Materials and Design, 51: 819:825, (2013). [16] Selvaraj D.P., Chandramohan P., Mohanraj M., “Optimization of Surface Roughness, Cutting Force and Tool Wear of Nitrogen Alloyed Duplex Stainless Steel in A Dry Turning Process Using Taguchi Method”, Measurement, 49: 205-215, (2014).[17] Thakur D.G., Ramamoorthy B., Vijayaraghavan L., “Study on The Machinability Characteristics of Superalloy Inconel 718 During High Speed Turning”, Materials & Design, 30: 1718-1725, (2009).[18] Yallese A.M., Chaoui K., Zeghibb N., Boulanouar L., Rigal J.F., “Hard Machining of Hardened Bearing Steel Using Cubic Boron Nitride Tool”, Journal of Materials Processing Technology, 209: 1092-1104, (2009).[19] Lima J.G., Avila R.F., Abrao A.M., Faustino M., Davimb J. P., “Hard Turning: AISI 4340 High Strength Low Alloy Steel and AISI D2 Cold Work Tool Steel”, Journal of Materials Processing Technology, 169: 388-395, (2005).[20] Bouchelaghem H., Yallese M.A., Mabrouki T., Amirat A., Rigal J.F., “Experimental Investigation and Performance Analyses of CBN Insert in Hard Turning of Cold Work Tool Steel (D3)”, Machining Science and Technology, 14: 471-501, (2010).[21] Suresh R, Basavarajappa S., Samuel G.L., “Some Studies on Hard Turning of AISI 4340 Steel Using Multilayer Coated Carbide Tool”, Measurement, 45: 1872-1884, (2012).[22] Çiçek A., Kara F., Kıvak T., Ekici E., “Evaluation of Machinability of Hardened and Cryo-Treated AISI H13 Hot Work Tool Steel With Ceramic Inserts”, International Journal of Refractory Metals and Hard Materials, 41: 461-469, (2013).[23] Li S., Xie Y., Wu X., “Hardness and Toughness İnvestigations of Deep Cryogenic Treated Cold Work Die Steel”, Cryogenics, 50: 89-92, (2010). [24] Ferreira R., Carou D., Lauro C.H., Davim J.P., “Surface Roughness Investigation in the Hard Turning of Steel Using Ceramic Tools”, Materials and Manufacturing Processes, 31: 648-652, (2016).[25] Palanisamy D., Senthil P.b, “A Comparative Study on Machinability of Cryo-Treated and Peak Aged 15Cr5Ni Precipitation Hardened Stainless Steel”, Measurement, 116: 162-169, (2018).[26] Lıu K., Shan Y., Yang Z., Lıangj., Lu L., Yang K., “Effect of Heat Treatment on Prior Grain Size and Mechanical Property of a Maraging Stainless Steel”, Journal of Materials Science & Technology, 22:769-774, (2006).[27] Ulaş H.B., “Experimental Determination of Cutting Forces and Surface Roughness when Turning 50CrV4 Steel (SAE 6150) and Modelling with the Artificial Neural Network Approach”, Transactions of the Indian Institute of Metals, 67: 867-879, (2014).
There are 1 citations in total.

Details

Primary Language English
Subjects Engineering
Journal Section Research Article
Authors

Barış Özlü 0000-0002-8594-1234

Halil Demir 0000-0002-9802-083X

Mustafa Türkmen 0000-0002-9402-2459

Publication Date December 1, 2019
Submission Date November 6, 2018
Published in Issue Year 2019 Volume: 22 Issue: 4

Cite

APA Özlü, B., Demir, H., & Türkmen, M. (2019). The Effect of Mechanical Properties and the Cutting Parameters on Machinability of AISI 5140 Steel Cooled at High Cooling Rates After Hot Forging. Politeknik Dergisi, 22(4), 879-887. https://doi.org/10.2339/politeknik.479345
AMA Özlü B, Demir H, Türkmen M. The Effect of Mechanical Properties and the Cutting Parameters on Machinability of AISI 5140 Steel Cooled at High Cooling Rates After Hot Forging. Politeknik Dergisi. December 2019;22(4):879-887. doi:10.2339/politeknik.479345
Chicago Özlü, Barış, Halil Demir, and Mustafa Türkmen. “The Effect of Mechanical Properties and the Cutting Parameters on Machinability of AISI 5140 Steel Cooled at High Cooling Rates After Hot Forging”. Politeknik Dergisi 22, no. 4 (December 2019): 879-87. https://doi.org/10.2339/politeknik.479345.
EndNote Özlü B, Demir H, Türkmen M (December 1, 2019) The Effect of Mechanical Properties and the Cutting Parameters on Machinability of AISI 5140 Steel Cooled at High Cooling Rates After Hot Forging. Politeknik Dergisi 22 4 879–887.
IEEE B. Özlü, H. Demir, and M. Türkmen, “The Effect of Mechanical Properties and the Cutting Parameters on Machinability of AISI 5140 Steel Cooled at High Cooling Rates After Hot Forging”, Politeknik Dergisi, vol. 22, no. 4, pp. 879–887, 2019, doi: 10.2339/politeknik.479345.
ISNAD Özlü, Barış et al. “The Effect of Mechanical Properties and the Cutting Parameters on Machinability of AISI 5140 Steel Cooled at High Cooling Rates After Hot Forging”. Politeknik Dergisi 22/4 (December 2019), 879-887. https://doi.org/10.2339/politeknik.479345.
JAMA Özlü B, Demir H, Türkmen M. The Effect of Mechanical Properties and the Cutting Parameters on Machinability of AISI 5140 Steel Cooled at High Cooling Rates After Hot Forging. Politeknik Dergisi. 2019;22:879–887.
MLA Özlü, Barış et al. “The Effect of Mechanical Properties and the Cutting Parameters on Machinability of AISI 5140 Steel Cooled at High Cooling Rates After Hot Forging”. Politeknik Dergisi, vol. 22, no. 4, 2019, pp. 879-87, doi:10.2339/politeknik.479345.
Vancouver Özlü B, Demir H, Türkmen M. The Effect of Mechanical Properties and the Cutting Parameters on Machinability of AISI 5140 Steel Cooled at High Cooling Rates After Hot Forging. Politeknik Dergisi. 2019;22(4):879-87.

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