Effect of cutting edge geometry and workpiece hardness on surface generation in the finish hard turning of AISI 52100 steel

An experimental investigation was conducted to determine the effects of too l cutting edge geometry and workpiece hardness on the surface roughness and cutting forces in the finish hard turning of AISI 52100 steel. Cubic boron nitride inserts with various representative cutting edge preparations and through-hardened AISI 52100 steel bars were used as the cutting tools and w orkpiece material, respectively. This study shows that the effect of edge g eometry on the surface roughness and cutting fords is statistically signifi cant. Specifically, large edge hones result in higher average surface rough ness values than small edge hones, due to increase in the extent of ploughi ng compared to shearing. The effect of the two-factor interaction of the ed ge geometry and workpiece hardness on the surface roughness is also found t o be important. Additionally, large edge hones result in higher forces in t he axial, radial, and tangential directions than small edge hones. It is al so shown that the effect of workpiece hardness on the axial and radial comp onents of force is significant, particularly for large edge hones. (C) 1999 Elsevier Science S.A. All rights reserved.