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REVIEW JOURNAL

CUBIC BORON NITRIDE TOOL WEAR IN


INTERRUPTED HARD CUTTING
MATA KULIAH
MANUFAKTUR, PERAWATAN DAN ALAT PRODUKSI

Dosen : Muslim Mahardika, ST, M.Eng, PhD.Eng

HERI SUHUD KUSTOYO

Kelas : A

TIKM-Oktober 2009

UNIVERSITAS GADJAH MADA


FAKULTAS TEKNIK
MAGISTER SISTEM TEKNIK
2009
1. Introduction

Cubic boron nitride CBN tool wear is one’s of advanced cutting material. It has
function to enable the hard machining technology, an alternative to costly abrasive-based
processes. There are two type of CBN. The first is CBN –H, it has properties 0.9 of volume
fraction of CBN grains with metallic binders e.g. cobalt. The second is CBN-L, it has
properties 0.5 to 0.7 volume fraction, with ceramic binders e.g . titanium nitride.

The purpose the experiment is to study the effect of CBN content, particularly in
cutting speed effects and frequency of interruption effects.

2. Experiment detail
a. Apparatus
1) BN 250
Product from sumitomo, it has 0.6volume fraction of CBN grains with
titanium nitride binder. The average grain size of BN250 is about 1 mm.
BN250 is type of CBN-L.
2) BZN6000
Product from GE Superabrasive, it has 0.92 volume fraction of CBN
particles bonded by cobalt. The average CBN grain size is about 2 mm.
BZN6000 is type of CBN-H.
3) Cutting Insert
Cutting inserts were 55o diamond shaped tungsten carbide substrates brazed
with CBN tips
4) Work Material
Work material were M50, a molybdenum based tool steel
5) Workpieces
Workpieces were 38 mm diameter and about 90 mm long bars. In order to
obtain interrupted cutting conditions, 6 mm x 6 mm slots were pre-
machined . on cylindrical surfaces along the axial direction Fig. 1 .
a. Workpieces heat treatment process
1) preheat at 982 oC for 40 min,
2) vacuum austenitizing at 1107 oC for 10 min,
3) nitrogen gas quenching,
4) tempering at 177 o C for 2 h,
5) cryogenic cooling at y101 oC for 2 h, and
6) double tempering at 527 o C for 2 h each cycle.
7) Final hardness was in the range of 62 Rc to 64 Rc.
a. Method / Procedure experiment
1) Feed rate and depth of cut were fixed at 12.5µm/rev and 50 µm.
2) Cutting speed was ranged from 2 m/s to approximately 8 m/s
3) Frequency of . interruption FI was 0 Hz i.e., continuous cutting , 35,70, or
140 Hz.
4) During cutting tests, workpieces were turned only in the range between 35
to 38 mm diameter to minimize variation in frequency of interruption.
5) Axial cutting length for each pass was 57 mm.

1. Results
a. Cutting speed effects
Fig. Figure Explanation
No.
2 Figure for BN250 tools at different cutting
speeds. Medium cutting speed, 4 m/s, had
gradually developed flank wear, while either
lower or higher cutting speeds showed rapid
tool wear. It only took about 3 min to reach
about 500 µm VBmax at 2 m/s.
3. Figure for BZN 6000 tools at different
cutting speeds. It show Flank wear and wear
rate increased with cutting speed. At 7.8 m/s,
VB max reached close to 700 µm in only 1
min cutting time.

4 Fig. 4 show that BN250 has longest tool life


when cutting speed exited between 2 and 8
m/s. contrary tool life of BZN6000
monotonically decreased with increasing
cutting speed. .

b. Frequency of interruption effects


Fig. Figure Explanation
No.
13 Fig. 13 plots tool life of the CBN tools at
different frequencies of interruption, with
tool life criterion of 500 µm VBmax . For
BN250, tool life decreased proportionally
with increasing frequency of interruption. In
contrast, tool life of BZN6000 was nearly
constant to frequency of interruption.

1. Conclussion

Tool life depend on cutting speed and frequency. From experiment we get different
wear characteristics between high CBN-H and low CBN-L CBN content tools. With
Taylor’s tool life equation, we get information tool life of CBN-L is optimized at a medium
cutting speed. In contrast, CBN-H shows a monotonic decrease of tool life with increasing
cutting speed. Moreover, CBN-H is less sensitive to interrupted cutting than CBN-L, which
shows consistent decrease of tool life with increasing frequency of interruption. It is
suggested that the higher hardness and fracture toughness of CBN-H result in greater
resistance to mechanical wear that becomes more dominant in interrupted cutting. However,
the metallic binder in CBN-H has high affinity with workpiece materials and, therefore,
results in rapid thermally activated wear at high cutting speeds.

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