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STUDY ON CUTTING FORCES AND SURFACE QUALITY IN

TURNING C45 STEEL

Adrian TRIF1 and

Alina-Ioana POPAN

2

Department of Manufacturing Engineering, Technical University of Cluj-Napoca, Romania,

e-mail: adrian.trif@tcm.utcluj.ro

Department of Manufacturing Engineering, Technical University of Cluj-Napoca, Romania,

e-mail: alina.luca@tcm.utcluj.ro

ABSTRACT: This study aims to present the main theoretical and practical aspects

regarding the study of roughness and cutting forces in the case of the external turning process

of C45 carbon steel. The content of the study presents general data on the turning operation,

various roughness - obtained from the turning process of C45 carbon steel, how the cutting

force and roughness forces are influenced by the cutting speed and the depth of the cut, but also

the simulation of the cutting process using the DEFORM 2D software.

KEYWORDS: steel, turning , forces, roughness, simulation

1 INTRODUCTION

In turning process when we talk about surfaces

we have three most important surfaces: work

surface which is the surface removed, the machined

surface which is the finish surface - obtained after

the tool passes and transient surface which is found

between work surface and machined surface (Fig.

1.1).

Fig. 1.1 The main surfaces in turning process

For a long life of tool the mechanical loads must

be lower than the maximum loads that the tool can

handle, the maximum load capacity of the tool is

given by the material from what is made of, the

coating material and the geometry.

Cutting speed, depth of cut, feed rate can make

the different between a good finished product and a

scrap; they can affect even the tool life. A higher

feed rate and depth of cut with a low cutting speed

can offer the best results, if a better productivity is

desired it can be obtained with a higher cutting

speed and low depth of cut and feed to reduce the

cutting force.

The cutting force is influenced by several

parameters like tool geometry, workpiece material,

and feed rate. By increasing these parameters, the

cutting force will increase but not in a dangerous

way for the cutting process, the feed rate having a

greater impact on chip thickness thing that means

that increasing feed rate the loads on the cutting

edge is increased.

A parameter which has a big impact on cutting

force is depth of cut, for example by tripling the

value of depth of cut, the cutting force will be

tripled to, but the loads on the tool will be the same

because the cutting edge in cutting action will be

increased to.

Another parameter which influences the cutting

force is the cutting speed, by increasing it the

cutting force decrease, a big problem appears when

the cutting speed decrease because the cutting force

increase and build-up edges appears, this

phenomenon is a good indicator of an inappropriate

cutting speed.

2 THE MATERIAL: C45 STEEL

This kind of steel is known for his tensile

strength and ductility, the carbon quantity which is

between 0.45% and 0.5% is added in manufacturing

process, a quenching and tempering process are

made to obtain a structure with a consistent tensile

strength.

For a good tempering and through-hardening

process the part cannot be bigger than 60 mm, the

nitriding process is useless to be done on C45

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because the alloying elements are not suitable for

this process.

The machinability of C45 is is influenced by

some factors like microstructure, content of carbon,

sulfur, manganese, for example a high quantity of

sulfur allow a high feed reducing the strain

hardening of the chip and maintaining a consistent

build up edge on the tool.

Fig. 2.1 Chemical composition of C45 steel

The used insert is CCMT 09T304 FG (TT5080):

Fig. 2.2. The workpiece and the insert

●General information about roughness in turning

of C45 carbon steel

The surface roughness is an important parameter

in every machining process, this parameter affects

different characteristics like tribological one,

frictional and most important, opinion the assembly

capabilities, the surface roughness is influenced by

different parameters like:

- Tool geometry;

- Depth of cut;

- Cutting speed;

- Feed rate;

- Workpiece’s microstructure;

- Rigidity of the machine;

The surface roughness has his impact to, on the

performance of produced machines, efficiency,

mechanical life, resistance against environmental

factors.

Lot of studies present by the experts show that

the geometry of the insert, the cutting force, feed

rate, have a major impact on the roughness of the

finished surface.

3 EXPERIMENTAL WORK

● Basic informations about experimental work

The experiment that consists in the turning

process of a carbon steel C45 shaft with the

diameter of 50 mm was rolled out at different depth

of cut, cutting speed and same feed rate in order to

analyze the cutting force and the surface roughness

resulted.

The machine used in the experiment was a

classical lathe model SPF-1500P from

Technical University of Cluj-Napoca, Faculty of

Machine Building.

The temperatures of cutting area in turning

process was also measured with the help Optris

Infrared Thermometer LS, the thermometer is

presented in Fig. 3.1, with an accuracy of ±2.5 °C (-

35 to -20°C), ±1.5 °C (-19.9 to 20°C), ±0.75 °C

(20.1 to 100°C), ±0.75 °C (100.1 to 900°C)

Fig. 3.1 Optris Infrared Thermometer LS

●The experiment

The experiment consists of twelve attempts, in

every single one the depth of cut and cutting speed

being different, the values varying for depth of cut

from 0.5 to 2 mm and for cutting speed from 250 to

1220 rot/min.

●The cutting process

The cutting force and temperature were

measured with the help of “XKM 2000” which is

the soft of the TELC DKM 2010 dynamometers

through which the cutting force during the

machining process was represented in form of a

graph and with “Optris Connect” which is the

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software of the thermometer presented above, the

value of temperature resulted being represented in a

graphic form (Fig. 3.2, Fig. 3.3.).

For measuring the roughness of the finished

surface the Mitutoyo SJ-210 rugosimeter was used

in these experiments, the rugosimeter is easy to use

and very compact, this thing helping in measuring

the roughness of any kind of surface even with

complex shapes.

Fig. 3.2. Measured cutting forces and temperatures (Experiment 1)

Similar graphs were obtained for experiments 2-12

4 RESULTS INTERPRETATION

The results was centralized and introduced in a

specialized software named DESIGN EXPERT,

with the help of this software the impact of the

cutting speed and depth of cut on the roughness and

cutting force was analyzed. This software is capable

to optimize the value of chosen parameter in order

to have the best results possible. With the help of

this software 3D viewing and 2D interactive

contours can be explored and the numeric

optimization function can be used for dozens of

simultaneous responses.

Fig. 4.1. The interface of DESIGN EXPERT with

experimental data

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The mathematical model for the Design Expert

software is ANOVA, and the graphical analyzes

will be presented below.

● Cutting force analysis

Fig. 4.2. Cutting force variation along contour lines,

depending of depth of cut and cutting speeds

Fig. 4.3. The comparison between predictive

evolution of cutting speed and the actual one

Fig. 4.4. The 3D representation of the variation of

cutting force depending on values of the depth of cut

and cutting speed

Fig. 4.5. The influence of depth of cut and cutting

speed on cutting force

As can be observed the depth of cut has the

major impact on cutting force this is very well

represented in Fig. 4.5 where can be noticed that the

cutting force increase just when the depth of cut is

modified, the cutting force remain the same at all

value of the cutting speed where the depth of cut is

constant. The best cutting force was obtained in two

experiments as can be seen in Fig. 4.5 the depth of

cut was 1.20 mm and the value of cutting speed was

560 [U/min] this observation has a better

representation in 3D mode in Fig. 4.4. this result

being represented on 3D surface with a red point.

A low cutting speed is unfavorable because the

build-up edge can appear and a too big one

contribute to a bigger wear of the tool.

●Analysis of the surface roughness

Fig. 4.6 Surface roughness variation along contour

lines depending of depth of cut and cutting speed

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Fig. 4.7. The comparison between predictive evolution

of surface roughness and the actual one

Fig. 4.8. The 3D representation of the variation of

surface roughness depending on values of the depth of

cut and cutting speed

Fig. 4.9. The influence of depth of cut and cutting

speed on surface roughness

As can be observed the depth of cut and cutting

speed has almost the same impact on surface

roughness this is very well represented in Fig. 4.9.

where can be noticed that the surface roughness

increase changing the values of one of the

parameters, the surface roughness can become

better by increasing the cutting speed or by

increasing the depth of cut. The best surface

roughness was obtained in two experiments as can

be seen in Fig. 4.5, first when the depth of cut was 2

mm and the value of cutting speed was 250 [U/min]

and the second when the depth of cut was 0.50 mm

and the value of cutting speed was 1220 [U/min]

this observation has a better representation in 3D

mode in Fig. 4.4 this result being represented on 3D

surface with a red point.

5 SIMULATION OF THE TURNING

PROCESS WITH DEFORM 2D

SOFTWARE

● Presentation of DEFORM 2D software

The software can simulate the temperature and

cutting force resulted after machining process based

on different parameters like cutting speed, depth of

cut, feed to calculate the cutting force, temperatures,

chip tension and semi product .

Based on the finite element method, deform has

proved to give a realistic results after simulation for

industrial application. Deform 2D is the most

widely used simulation program in the world by

research institutes and manufacturers.

Features of the software:

- Library of tool and semi-finished material

- Automatic generation of time cutting efforts

- Automatic generation of stress, deformations,

temperature and damage of the semi-finished piece

material

- Geometries of own or imported from other cad

software

- 2D and 3D modeling of plastic deformation and

on-line deformation process

● The simulation of cutting process

Three simulation will be done with different

values of cutting parameters, the cutting tool will be

considered rigid because the software does not

calculate the deformation of the tool and for the

piece the plastic environment will be chose

considering the fact that the elastic returns of the

material are negligible.

To start the simulation in the Deform 2D the

cutting regime must be defined, the tool must be

defined and the blank must be defined to.

In the next figures will be presented the process

simulation steps, will be presented the steps just for

one simulation for the other the steps being the

same, the only difference being the values of cutting

parameters which are presented in Tab. 5.1.

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Table 5.1

The values of cutting parameters used in simulations

Number of

experiment

Depth of

cut

Cutting

speed

Feed rate Diameter of

work piece

Simulation 1 0.5 250 0.17 50

Simulation 2 1.2 560 0.17 50

Simulation 3 2.0 1220 0.17 50

Fig. 5.1 Establishing the cutting parameters

Fig. 5.2 Establishing the geometrical parameters

of the tool

Fig. 5.3. The coating material

The tool is coated with two different layers, one

of TiCN and one of Al203 how can be seen from the

Fig. 6.4.

Fig. 5.4 Establishing the geometrical parameters of

the workpiece

These are the steps which mast be followed to

can simulate a machining process in Deform 2D

software.

●The resultes of the simulations

The main purpose of the simulation of the

orthogonal cutting process using DEFORM 2D

software was to estimate the process temperature

and the forces during the cutting process, as well as

to compare these results with those measured in the

experiment.

After the pre-processor finalization the

simulation can start, and after simulations have been

analyzed load on x axis, load on y axis, and the

temperatures, being presented in a graphical form.

The results of the simulations will be presented

togheter based on parameter analyzed and in the

order specified in Tab. 5.1, will be presented the

figure where the measured parameter has the

biggest value.

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a

b

Fig. 5.5 The x load resulted on simulations 1 and 2

(a,b)

c

d

Fig. 5.6 The y load resulted on simulations 1and 2

(c,d)

e

f

Fig. 5.7 The x and y loads resulted on simultation 3

(e,f)

6 CONCLUSIONS

The study aim to present an experimental study

and a modeling of the cutting process namely the

turning process, using the method with finite

element, to obtain some process output parameters,

necessary to establish the theoretical model of

surface roughness and cutting force in order to

make a comparison between them and the real one.

The results obtained after experiments was

compared with the results obtained after the

simulation, the simulation was realized with the

help of DEFORM 2D software, a software which

allow high-precision model for a reliable

monitoring.

With DEFORM 2D simulation of the turning

process were performed and using the finite element

method of the external longitudinal turning

operation of a carbon steel semi-product.

In the experimental study which number twelve

attempts, the influence of the cutting regime

parameters especially of the cutting speed and the

depth of cut, in the case of dry turning of C45

carbon steel was analyzed in terms of cutting force,

surface roughness and temperature.

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From the results obtained in this work and based

on current knowledge, the following conclusion can

be derived:

- In this paper is related the characteristics of the

turning process, which presents the regime in terms

of cutting force and surface roughness at external

turning.

- The purpose of this work was to know how the

behavior of C45 carbon steel from the point of view

of cutting force and the surface roughness resulted.

- In term of cutting force, was observed that the

depth of cut has the biggest impact on this

parameter, even at high or low cutting speed the

cutting force is pretty constant, but by modifying

the depth of cut the cutting force modify sizably

from one value of this parameter to another, to

improve the cutting force the following steps are

recommended:

Reduce the depth of cut

Increase the cutting speed

-The temperature of the simulation process was

similar to the temperature measured using the

optical pyrometer

- The surface roughness is influenced pretty equal

by both parameters, the cutting speed and the depth

of cut, it was observed that it was obtained a good

surface quality when the cutting speed had a higher

value and the depth of cut had a lower one, a bad

surface roughness was observed when the depth of

cut and the cutting speed had both a low value, to

improve the surface quality the following steps are

recommended:

A correlation between the cutting speed and the

depth of cut is important to exist

Increase the cutting speed

Increase the depth of cut

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