Experimental investigation of hard spline milling using a newly developed disk cutter

Document Type : Research Paper

Authors

Department of Mechanical Engineering, Faculty of Engineering, Ferdowsi University of Mashhad, Mashhad, Iran

Abstract

Machining hardened steels is a common requirement in various industries. This includes gearing and spline cutting on hardened steel parts at high speeds. Traditionally, gearing tools were made of high-speed steels, which made them suitable only for gearing at low cutting speeds with coolant. However, hard gearing using disk cutters with interchangeable carbide inserts is a new and flexible method for machining various types of splines and gears without special equipment. In this research, a disk cutter with four carbide cutting inserts is designed and manufactured. Experimental analysis is performed to assess the applicability of the developed cutter in machining splines on hardened steel axle shafts. Workpieces made of DIN 60SiMn5 steel with a hardness of 46 HRC and AISI 1552 steel with a hardness of 61 HRC are machined using two types of carbide inserts in wet and dry cutting conditions. Results show achieved surface roughness values in the range of 0.161 μm < Ra < 0.376 μm, which is an indication of a very good surface quality. Also, ANOVA methods are used to assess the impact of input parameters on machined surface roughness and cutting tool wear. The analysis shows that surface roughness is most affected by insert type, while use of coolant is the most effective parameter on tool wear. This research also proves applicability of dry milling as a sustainable and environmentally friendly method for spline cutting on hardened steels.

Keywords

[1]           S. Liang, A. J. Shih, 2015, Analysis of machining and machine tools, Springer,
[2]           F. Gong, J. Zhao, X. Ni, C. Liu, J. Sun, Q. Zhang, Wear and breakage of coated carbide tool in milling of H13 steel and SKD11 hardened steel, SN Applied Sciences, Vol. 1, No. 9, pp. 1-12, 2019.
[3]           K. Fukunaga, S. Inoue, M. Yonekura, I. Sakuragi, Direct dry hobbing of high hardened material: RGC (Round bar gear cutting) method, in Proceeding of, 551-557.
[4]           D. Sari, F. Klocke, C. Löpenhaus, Gear finish hobbing: potentials of several cutting materials, Production Engineering, Vol. 9, No. 3, pp. 367-376, 2015.
[5]           B. Karpuschewski, M. Beutner, M. Köchig, M. Wengler, Cemented carbide tools in high speed gear hobbing applications, CIRP Annals, Vol. 66, No. 1, pp. 117-120, 2017.
[6]           T. Glaser, T. Körner, J. Sapparth, M. Wennmo, Hard Machining of Spur Gears with the InvoMillingTM Method, Journal of Manufacturing and Materials Processing, Vol. 2, No. 3, pp. 44, 2018.
[7]           L. Prasad, 1995, Handbook of mechanical design, Tata McGraw-Hill Education,
[8]           S. P. Radzevich, 2017, Gear cutting tools: science and engineering, CRC Press,
[9]           ZCC Cutting Tools Europe Catalogue, Accessed Oct. 1, 2021; http://zccct.com.ua/wp-content/uploads/2020/01/Turning.pdf.
[10]         J. P. Davim, 2008, Machining: fundamentals and recent advances, Springer Science & Business Media,
[11]         J. P. Davim, 2011, Machining of hard materials, Springer Science & Business Media,
[12]         J. Lima, R. Avila, A. Abrao, M. Faustino, J. P. Davim, Hard turning: AISI 4340 high strength low alloy steel and AISI D2 cold work tool steel, Journal of Materials Processing Technology, Vol. 169, No. 3, pp. 388-395, 2005.
[13]         C. Richt. A new edge on gear milling, Accessed Oct. 1, 2021; https://gearsolutions.com/features/a-new-edge-on-gear-milling/.
[14]         J. Gerth, M. Larsson, U. Wiklund, F. Riddar, S. Hogmark, On the wear of PVD-coated HSS hobs in dry gear cutting, Wear, Vol. 266, No. 3-4, pp. 444-452, 2009.
[15]         M. Stipkovic Filho, M. A. Stipkovic, É. C. Bordinassi, S. Delijaicov, S. L. R. de Almeida, Experimental numerical model of roughness in finishing face milling of AISI 4140 hardened steel,  in: Improved Performance of Materials, Eds., pp. 83-91: Springer, 2018. 
Volume 53, Issue 1
March 2022
Pages 116-125
  • Receive Date: 13 November 2021
  • Revise Date: 06 January 2022
  • Accept Date: 02 February 2022