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Numerical analysis of the effect of tool wear on surface integrity during hard turning

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Abstract

The white layer formed during hard turning deteriorates surface integrity, thereby severely affecting the fatigue life of machined parts. A 2D FEM-based simulation model has been developed to simulate cutting temperature profiles in workpieces for the prediction of white layer thickness developed below the machined surface. Machining was simulated for fresh and worn tools with predefined flank wear. The temperature profile generated in the workpiece was analyzed for the critical temperature for phase transformation leading to white layer formation. The critical temperature was found to be deeper in the subsurface with an increase in cutting speed and wear, indicating a thicker subsurface white layer. Experimental observations using fresh tools were found very close to the simulation results. The model was extended to simulate temperature profile and predict the white layer for machining with tools having predefined tool flank wear.

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Authors and Affiliations

  1. School of Mechanical Sciences, IIT Bhubaneswar, Argul, Jatni, Odisha, 752050, India

    Rupak Kumar Nayak, Gaurav Bartarya & Manas Ranjan Sahoo

Authors
  1. Rupak Kumar Nayak
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  2. Gaurav Bartarya
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  3. Manas Ranjan Sahoo
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Correspondence to Gaurav Bartarya.

Additional information

Recommended by Editor Hyung Wook Park

Gaurav Bartarya earned his master’s and doctorate degrees from Indian Institute of Technology Kanpur, India. He is currently working as Assistant Professor at the Indian Institute of Technology Bhubaneswar, India. His preliminary area of interest is conventional machining of hard materials. He has worked extensively on surface integrity issues in hard turning of steel, concerned with process performance modeling and surface integrity issues such as white layer and tensile residual stresses prevailing during hard turning. He also works in advanced machining processes, incremental forming, and reverse engineering.

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Nayak, R.K., Bartarya, G. & Sahoo, M.R. Numerical analysis of the effect of tool wear on surface integrity during hard turning. J Mech Sci Technol 35, 1215–1222 (2021). https://doi.org/10.1007/s12206-021-0235-7

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  • DOI: https://doi.org/10.1007/s12206-021-0235-7

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