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Procedia CIRP 45 (2016) 15 18

3rd CIRP Conference on Surface Integrity (CIRP CSI)

Process controls for surface integrity generated by hard turning

Rahul G. Chaudharia*, Fukuo Hashimotoa
a
The Timken Company, 4500 Mount Pleasant St. NW, North Canton, OH 44720, USA

* Corresponding author. Tel.: +1-234-262-2352; fax: +1-234-262-2282. E-mail address: Rahul.chaudhari@timken.com

Abstract

An investigation was conducted on the evolution of the residual stresses and re-hardened white layer during finish hard turning.
The residual stress pattern is dominated by changes in cutting forces resulting from tool wear. Increased flank wear accelerated
normal sliding force generating tensile residual stress at the surface and reducing the magnitude of compressive stress below the
surface. However, very high flank wear yielded maximum below-surface compressive residual stress. Increased tool wear
beyond a critical value led to discontinuity in the relationship between normal and tangential forces. This paper proposes a new
tool-life criterion for controlling surface integrity in finish hard turning.
2016 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
2016 The Authors. Published by Elsevier B.V.
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the scientific committee of the 3rd CIRP Conference on Surface Integrity (CIRP CSI)
Peer-review under responsibility of the scientific committee of the 3rd CIRP Conference on Surface Integrity (CIRP CSI)
Keywords: Hard turning, Surface integrity, Process control

1. Introduction The present finish hard turning investigation was

Finish hard turning has emerged as an alternative to
grinding for the machining of hardened steels. Hard turning
offers significant cost benefits because of its reduced capital
investment, lower setup cost and lower tooling cost, which
have rapidly expanded the processs applications. Hard
turning has been found to induce compressive residual
stresses at the surface. In addition, rolling contact fatigue tests
have shown that hard turning provides equal - or in some
cases, better - fatigue performance than grinding [1,2].
However, some challenges remain in using hard turning
applications to completely finish precision components such
as the functional surfaces of bearings.
The surface integrity generated by hard turning was found
to depend largely on the tools edge geometry [1,3,4]. Since
tool wear affects the edge geometry, it can significantly
change the properties of the hard turned surface. Previous
investigations have reported that hard turning with worn tool
can result in tensile residual stresses at the surface. Also, the
depth of the white re-hardened layer was found to increase
with tool wear [3-6]. Therefore, in order to control the
functional performance of the surfaces produced by hard
turning it is critical to understand the onset of white layer
formation during the finish hard turning process.
undertaken to establish criteria for useful tool life that will
result in appropriate surface integrity of the finished
components. Experimental results are presented that show the
effect of tool wear on the properties of hard turned surfaces.
An analysis of these results indicates that, after certain levels
of tool wear are reached, acceleration of normal force limits
the useful life of the cutting tool in finish hard turning.
Finally, a method to control the performance of the hard
turning process by monitoring and detecting the change in
normal force is discussed to define the useful tool life.
2. Experimental setup and results
Experiments were performed to monitor the change in
cutting forces and characteristics of the hard turned surface
with insert wear. These experiments were conducted on a
CNC lathe using AISI 4319 and 52100 alloy steels hardened
to 58-62 HRC. PCBN inserts (CBN particle size 3-5 m,
CBN content 45%-65%) with 0.4 mm nose radius, chamfer
angle of 15q~ 25q and 5 Pm edge honing were used. A cutting
speed of 140 m/min with feed of 0.1mm/rev and depth of cut
of 0.1 mm was used. A water soluble coolant with 4 bar
pressure was used to control the bulk temperature of the work
piece and assist in chip control. Cutting forces in the normal,
tangential and axial directions were measured using a Kistler

2212-8271 2016 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the scientific committee of the 3rd CIRP Conference on Surface Integrity (CIRP CSI)
doi:10.1016/j.procir.2016.02.357
16 Rahul G. Chaudhari and Fukuo Hashimoto / Procedia CIRP 45 (2016) 15 18

9121 dynamometer. The magnitude and change of cutting
force in the axial direction was lowest and hence this data is
not included. Residual stresses were measured using X ray
diffraction method. Tool wear was measured on the machine
using an optical microscope. Figure 1 shows the change in
normal force Fn and tangential force Ft with tool flank wear.
Although both cutting forces increase with insert wear, the
magnitude off change is different in each direction. Initially,
normal forcee tends to increase with higher flank wear, but
after a certain
in amount of flank wear the rate of change of
normal force increases rapidly. The rate of increase of
tangential force with flank wear is nearly constant. For the
of about 0.025 mm the residual stress was compressive. The
occurrence of higher tensile stress with the progression of
flank wear indicates increased heat generation at the work tool
interface. The depth of heat penetration to the workpiece was
very shallow due to the small contact zone and short
machining time; hence, the presence of tensile stress was
limited only to very shallow depths near the surface. It is also
interesting to note that very large flank wear generated deep
compressive stresses in the work surface mainly due to the
severe plastic deformation.
1400
Work material: AISI 4319 HRc 58-62

Circumferential residual stress, MPa

same set of experiments the rate of change of flank wear was 1050
observed to be almost linear with cutting time. The change in Flank wear
Prior to hard turn New insert
cutting forces was very similar for both the materials. It is 700
0.04 mm 0.08 mm
important to note that these experiments were conducted 0.11 mm 0.18 mm
using shorter cutting times to precisely monitor the evolution 350
of flank wear and the resultant cutting forces. Also, efforts
were focused on minimizing the error in the flank wear 0
measurement by measuring the wear on the machine without
-350
removing the cutting tool. It is interesting to note that in both
materials, normal force started rapidly increasing after about -700
0.1 mm of tool flank wear. Similar results showing a rapid
increase in normal force with the progression of flank wear -1050
have been previously reported; even though these
investigations did not focus on the discontinuity in normal -1400
force[3,7,8,9]. 0 0.025 0.05 0.075 0.1 0.125
Depth below surface, mm
450
Work material:Hardened alloy steel HRc 58-62
Figure 2: Residual stress vs flank wear AISI 4319
400
Ft
350 1400
Work material: AISI 52100 HRc 58-62
Fn
300
Cutting force, N

1050 Flank wear

Circumferential residual stress, MPa

Prior to hard turn New insert

250 700 0.07 mm 0.1 mm
0.18 mm 0.3 mm
200 350
150 0
100
-350
50 AISI 4319 Fn Ft
AISI 52100 Fn Ft -700
0
0 0.1 0.2 0.3 0.4 -1050
Flank wear, mm
-1400
Figure 1: Cutting force vs flank wear
0 0.025 0.05 0.075 0.1 0.125
Depth below surface, mm
3. Surface integrity in hard turning
Figure 3: Residual stress vs flank wear AISI 52100

The effect of tool flank wear on circumferential residual

stress is shown in Figures 2 and 3 for the AISI 4319 and AISI
52100 steel materials, respectively.
Independent of the surface stress condition prior to hard
turning, a compressive residual stress was observed on the
surface after hard turning with a new insert. However, as
flank wear developed, tensile stress was observed at the
surface. It is important to note that this tensile stress occurred
only in the shallow region beneath the surface. Below a depth
Figure 4 shows the microstructure of the hard turned
surface at different values of flank wear. The formation of
white layers on the hard turned surface is attributed to plastic
deformation as well as thermal transformation of the work
surface during the hard turning process [3,5]. The main
objective of this investigation was identifying the onset of
thermal transformation at the work surface. As seen in Figure
4, after about 0.1 mm of flank wear a white layer is observed
on the surface; a dark layer was visible immediately under
 Rahul G. Chaudhari and Fukuo Hashimoto / Procedia CIRP 45 (2016) 15 18 17

this white layer. The occurrence of the dark layer indicates after a certain amount of flank wear, SEM pictures of the
re-tempering and confirms that the white layer in this case is cutting edge at different cutting times were taken.
associated with re-hardening. As seen in Figure 6(a), with 0.06mm of flank wear, a crater
Figure 5 shows the progress of the re-hardened layer with was developed on the tool, but the area of the cutting edge
the flank wear. At smaller values of flank wear below 0.1 containing the original 20q chamfer still exists. Figure 6(b)
mm, no white layer was observed on the surface. However, shows that at 0.11mm of flank wear, only a very small part of
beyond this value of flank wear, a continuous white layer with the original cutting edge remains on the tool.
0
uniform thickness was observed on the hard turned surface. 0
20 Chamfer 20 Chamfer
From Figures 1 and 5 it can be seen that a uniform white layer
appeared on the surface at about the same value of flank wear
that corresponds to the acceleration of normal force.
Front view Side view

(a) cutting edge with 0.060 mm flank wear

(1) Flank wear = 0 mm (1) Flank wear = 0 mm

White layer White layer

(b) cutting edge with 0.11 mm flank wear

(2) Flank wear = 0.11 mm (2) Flank wear = 0.1 mm

White layer White layer

(c) cutting edge with 0.18 mm flank wear
Work Material: AISI 4319

Figure 6: SEM images showing progression of flank wear.

(3) Flank wear = 0.18 mm (3) Flank wear = 0.22 mm
(a) Work material: 4319 (b) Work material: 52100 Finally, Figure 6(c) shows that after 0.18 mm of flank wear
the original cutting edge completely disappears. The normal
Figure 4: Microstructure of hard turned surface force linearly increases with the flank wear; but when the
cutting edge deteriorates, the normal force accelerates to
The formation of this re-hardened layer limits the useful life higher values. Previous investigations [1] have shown that a
of hard turning cutting tools in finishing bearings and other cutting edge with a large honing radius or extremely negative
power transmission components that are subject to fatigue. chamfer produces increased compressive residual stresses at a
deeper layer. A worn and blunt cutting edge; such as that
0.006 seen in Figure 6(c); also resulted in very deep compressive
Work material:
Hardened alloy steel HRc 58-62 residual stresses as shown in Figure 2.
0.005
Depth of white layer, mm

Based on Figure 1, the normal and tangential forces during

AISI 4319 AISI 52100 hard turning can be considered to consist of cutting (c) and
0.004 sliding (sl) components.
Fn = Fn,c + Fn,sl (1)
0.003 Ft = Ft,c + Ft,sl (2)
The linear relationship between the cutting forces and flank
0.002 wear that exists until the acceleration of normal force begins;
indicates that the average contact pressure p between the flank
0.001 wear land and work is constant. Defining A as the flank wear-
flat area, Equations (1) and (2) can be written as
0 Fn = Fn,c + pA (3)
Ft = Ft,c + pA (4)
0.1
0
0.04
0.08
0.11
0.18

0
0.07

0.16
0.22

where is the coefficient of sliding friction. By combining

Flank wear, mm Equations (1) through (4) the normal force can be expressed as
Fn = (1/) (Ft - Ft,c )+ Fn,c (5)
Figure 5: Depth of white layer vs flank wear Equation 5 shows that normal force Fn and tangential force
Ft have a linear relationship with a slope of (1/). For the
4. Discussion experimental data in this study, a graph of normal versus
tangential force as shown in Figure 7 certainly indicates a
In order to investigate the rapid increase of normal force
18 Rahul G. Chaudhari and Fukuo Hashimoto / Procedia CIRP 45 (2016) 15 18

linear relationship. As the flank wear reaches a critical value, 5. Conclusion

the rate of growth of normal force changes from (1/1) to
(1/2). From the experimental results shown in Figure 7, Experiments were conducted to establish a criterion for
useful tool life related to the surface integrity of the finish
estimated values of 1 and 2 are between 0.15 ~ 0.2 and 0.45
hard turned surface. The changes in cutting forces associated
~ 0.6 respectively. A re-hardened white layer is observed
with tool flank wear were analyzed. It was observed that the
beyond this discontinuity. A similar discontinuity in the rate of increase of normal force suddenly changes after a
relationship of normal and tangential forces was observed in certain amount of flank wear corresponding to deterioration of
grinding and was associated with the onset of thermal damage the original cutting edge of the tool. The acceleration of
[10]. normal force leads to the onset of a re-hardened white layer
on the finish hard turned surface. The ratio of normal to
tangential force can be used to detect the discontinuity in the
450
relationship between normal and tangential forces and define
Work material:
400 Hardened alloy steel HRc 58-62
useful tool life.
350
4.5
AISI 4319
300 Work material:
Normal force, N

AISI 52100 4 Hardened alloy steel HRc 58-62

250 3.5
200 AISI 4319
3

Force ratio, Fn/Ft

AISI 52100
150 2.5
100 2
50 1.5
0 1
0 25 50 75 100 125
0.5
Tangential force,N
0
Figure 7: Normal vs tangential force 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35
Flank wear, mm
Based on the above discussion of changes in the properties
of hard turned surface, it is proposed that in order to avoid the
Figure 8: Force ratio vs flank wear
re-hardened white layer, the useful tool life for finish hard
turning be limited to a flank wear value corresponding to the
acceleration of normal force. The value of flank wear at References
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