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642 Vol. 122, NOVEMBER 2000 Copyright 2000 by ASME Transactions of the ASME
Journal of Manufacturing Science and Engineering NOVEMBER 2000, Vol. 122 643
than the 22.9 m hone for almost all corresponding factor level
combinations. In other words, for a given feed rate, an increase in
edge hone results in more compressive values of residual stress
for all normal components of stress. Additionally, for a given edge
preparation, increasing the feed usually causes the axial residual
stress to become more tensile less compressive. These tables Fig. 7 Effect of edge preparation and feed rate on hoop stress
also show that the 121.9 m edge and 25.4 m chamfer result in 41 HRC workpiece
shear stresses of greater magnitude than the 22.9 m edge. Fi-
nally, these tables show that stresses in the radial direction are
generally smaller than the other stress components. Because the
axial and hoop components of residual stress have a clear physical
interpretation, the effects of edge hone and hardness on these
components are examined in greater detail.
4.1 Effect of Edge Preparation on Residual Stress
Graphs of surface residual stress in the 11 axial and 22 hoop
directions are shown in Figs. 58 below. These figures show the
Journal of Manufacturing Science and Engineering NOVEMBER 2000, Vol. 122 645
5 Discussion
5.1 Microstructural Correlation. Microstructural analysis
reveals that three basic microstructural patterns exist on the work-
Fig. 9 Effect of hardness and feed rate on axial stress22.9 piece surface see Fig. 13 for example, including: 1 continuous
m hone
white layers, 2 intermittent white layers, and 3 dark layers.
These layers are created by heating and subsequent cooling of the
workpiece material during the cutting process. White layers are
Fig. 10 Effect of hardness and feed rate on axial stress121.9 Fig. 13 Continuous white layer121.9 m hone, 0.15 mmrev
m hone feed, 57 HRC workpiece
composed mostly of fine-grained, untempered martensite that re- tions. For example, the large edge hone tool 121.9 m hone
sists etching and appears white when viewed with an optical mi- forms continuous white layers on the surface of the workpiece for
croscope 18. White layers are created by heating of the work- both hardness values and for all feeds, resulting in compressive
piece material above the transformation temperature and residual stress in the axial and hoop directions. Representative
subsequent rapid cooling during the cutting process. Dark layers examples of continuous white layers are shown in Figs. 13 and 14.
are composed of over-tempered martensite, which etches easily. Note the effect of feed on white layer thickness in Fig. 14. This
These layers are created by heating of the workpiece below the can be related to a greater degree of heating which austenitizes a
transformation temperature. Dark layers are typically located deeper layer, which can then quench to a thicker layer of marten-
beneath continuous white layers and below and adjacent to inter- site. This microstructure-residual stress correlation is in agreement
mittent white layers. Finally, the interior surface of the workpiece with that reported by Abrao and Aspinwall 21 for hard turning
is revealed to be tempered martensite. of 52100 steel 62 HRC with different tool materials, and more
Table 4 provides a summary of microstructural features ob- recently by Matsumoto et al. 37 for turning of case-carburized
served on the surface of the workpiece for all tests. Stress com- bearing steel 5862 HRC using a honed CBN tool.
ponents in the axial and circumferential direction are included to The primary reason for compressive residual stress formation in
allow for correlation of microstructures with surface residual samples exhibiting continuous white layers is volume expansion
stress. It also shows the correlation between the strain-free inter- accompanying phase transformation 38,39. During machining,
planar spacing (d 0 ) and workpiece microstructure. This parameter the tempered martensite in the workpiece surface transforms to
is significant because d 0 is used to determine residual strain for austenite. Rapid cooling results in the formation of untempered
triaxial residual stress analysis according to the equation provided martensite, which attempts to expand. The interior workpiece ma-
in Section 3.3. Variation in strain-free interplanar spacing with terial places the surface layer in residual compression.
microstructure can be explained by considering that the 211 Samples that show dark layers on the workpiece surface see
peak is a composite of separate 211 peaks from both martensite Fig. 15 normally correlate with tensile residual stress in the axial
and ferrite phases. This appears as a single broad peak because the and hoop directions. For feeds larger than 0.05 mm/rev the small
nominal spacings of these planes are very similar and each peak is edge radius tool 22.9 m hone generally forms a dark layer on
broadened by plastic deformation 33. the workpiece surface, resulting in tensile residual stress in the
Surface residual stresses in the axial and hoop directions corre- axial and hoop directions. This is true for both the 41 and 57 HRC
late with each microstructural pattern. Specifically, all samples workpiece materials. This correlation can be explained by consid-
that show continuous white layers on the surface of the workpiece ering the thermal expansion and subsequent cooling of the work-
display compressive residual stress in the axial and hoop direc- piece surface, constrained by the workpiece interior 5. Thermal
Journal of Manufacturing Science and Engineering NOVEMBER 2000, Vol. 122 647
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19 Matsumoto, Y., Barash, M. M., and Liu, C. R., 1986, Effect of Hardness on
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hard-turning. Specifically, the study yielded the following conclu- 175.
sions: 1 Large edge hone radius tools produce more compres- 20 Wu, D. W., and Matsumoto, Y., 1990, The Effect of Hardness on Residual
sive values of residual stress in the axial and hoop directions than Stresses in Orthogonal Machining of AISI 4340 Steel, ASME J. Eng. Ind.,
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small edge hone tools, 2 The resulting workpiece microstructure 21 Tonshoff, H. K., Wobker, H-G., and Brandt, D., 1995, Hard Turning
is a good indicator of the surface residual stress state, 3 Large Influences on Workpiece Properties, Trans. NAMRI/SME, Vol. XXIII, pp.
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in residual compression, 4 Small edge hone tools typically pro- 22 Abrao, A. M., and Aspinwall, D. K., 1996, The Surface Integrity of Turned
and Ground Hardened Bearing Steel, Wear, 196, pp. 279284.
duce over-tempered surface layers, which are in residual tension 23 Mittal, S., and Liu, C. R., 1998, A Method of Modeling Residual Stresses in
for low hardness 41 HRC steel and in residual compression for Superfinish Hard Turning, Wear, 218, pp. 2133.
high hardness 57 HRC steel. 24 Liu, C. R., and Mittal, S., 1998, Optimal Pre-Stressing the Surface of a
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25 Jang, D. Y., Watkins, T. R., Kozaczek, K. J., Hubbard, C. R., and Cavin, O.
Acknowledgments B., 1996, Surface Residual Stresses in Machined Austenitic Stainless Steel,
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26 Schreiber, E., and Schlicht, H., 1986, Residual Stresses After Turning of
Kasperik of Kennametal, Inc., and Kenny Lanxton of Valenite, Hardened Components, Proceedings of the International Conference on Re-
Inc., for the donation of CBN cutting tools, tool holders, and time sidual Stresses, Garnish-Partenkirchen FRG, pp. 853860.
and resources in measuring the edge preparation of the inserts. 27 Tonshoff, H. K., Wobker, H-G., and Brandt, D., 1995, Potential and Limita-
Journal of Manufacturing Science and Engineering NOVEMBER 2000, Vol. 122 649