切削刃的几何形状，工件的硬度的影响，进给速度和切削速度对表面粗糙度和力量完成硬化AISI H13钢的车削毕业课程设计外文文献翻译、中英文翻译、外文翻译

EFFECTSOFCUTTINGEDGEGEOMETRY,WORKPIECEHARDNESS,FEEDRATEANDCUTTINGSPEEDONSURFACEROUGHNESSANDFORCESINFINISHTURNINGOFHARDENEDAISIH13STEELTUGRULZEL,TSUKONGHSU,EROLZERENDEPARTMENTOFINDUSTRIALANDSYSTEMSENGINEERINGRUTGERS,THESTATEUNIVERSITYOFNEWJERSEY,NEWJERSEY08854USAABSTRACTINTHISSTUDY,EFFECTSOFCUTTINGEDGEGEOMETRY,WORKPIECEHARDNESS,FEEDRATEANDCUTTINGSPEEDONSURFACEROUGHNESSANDRESULTANTFORCESINTHEFINISHHARDTURNINGOFAISIH13STEELWEREEXPERIMENTALLYINVESTIGATEDCUBICBORONNITRITEINSERTSWITHTWODISTINCTEDGEPREPARATIONSANDTHROUGHHARDENEDAISIH13STEELBARSWEREUSEDFOURFACTORHARDNESS,EDGEGEOMETRY,FEEDRATEANDCUTTINGSPEEDTWOLEVELFRACTIONALEXPERIMENTSWERECONDUCTEDANDSTATISTICALANALYSISOFVARIANCEWASPERFORMEDDURINGHARDTURNINGEXPERIMENTS,THREECOMPONENTSOFTOOLFORCESANDROUGHNESSOFTHEMACHINEDSURFACEWEREMEASUREDTHISSTUDYSHOWSTHATTHEEFFECTSOFWORKPIECEHARDNESS,CUTTINGEDGEGEOMETRY,FEEDRATEANDCUTTINGSPEEDONSURFACEROUGHNESSARESTATISTICALLYSIGNIFICANTTHEEFFECTSOFTWOFACTORINTERACTIONSOFTHEEDGEGEOMETRYANDTHEWORKPIECEHARDNESS,THEEDGEGEOMETRYANDTHEFEEDRATE,ANDTHECUTTINGSPEEDANDFEEDRATEAREALSOAPPEAREDTOBEIMPORTANTESPECIALLY,SMALLEDGERADIUSANDLOWERWORKPIECESURFACEHARDNESSRESULTEDINBETTERSURFACEROUGHNESSCUTTINGEDGEGEOMETRY,WORKPIECEHARDNESSANDCUTTINGSPEEDAREFOUNDTOBEAFFECTINGFORCECOMPONENTSTHELOWERWORKPIECESURFACEHARDNESSANDSMALLEDGERADIUSRESULTEDINLOWERTANGENTIALANDRADIALFORCES1INTRODUCTIONHARDTURNING,MACHININGFERROUSMETALPARTSTHATAREHARDENEDUSUALLYBETWEEN4570HRC,CANBEPERFORMEDDRYUSINGPOLYCRYSTALLINECUBICBORONNITRIDEPCBN,COMMONLYCBNCUTTINGTOOLSASEXTENSIVELYREPORTEDINLITERATURE18RESEARCHRESULTSINTHELITERATURECONCERNINGMECHANISMOFSERRATEDCHIPFORMATIONINORDERTORELATEPROCESSCHARACTERISTICSANDSTABILITYOFCUTTINGTOTHECHIPSHAPESDURINGHARDTURNING919OTHERRESEARCHCONCERNINGWITHCOMPOSITION,TEMPERATURESANDWEARCHARACTERISTICSOFCBNCUTTINGTOOLS1,8,20,21,22,28ANDEFFECTSOFWORKMATERIALPROPERTIES,TOOLGEOMETRYANDCUTTINGCONDITIONSONSURFACEINTEGRITYOFTHEFINISHMACHINEDPARTS2328INDICATECHALLENGESINHARDTURNINGANDIDENTIFIESVARIOUSPROCESS,EQUIPMENTANDTOOLINGRELATEDFACTORSAFFECTINGSURFACEQUALITY,TOOLLIFEANDPRODUCTIVITYAFTERREVIEWINGTHELITERATURE,FACTORSAFFECTINGFORCES,TOOLWEAR/FAILUREANDROUGHNESSANDINTEGRITYOFTHEFINISHEDSURFACESINHARDTURNINGUSINGCBNCUTTINGTOOLSANDTHEIRINFLUENCESONEACHOTHERAREILLUSTRATEDWITHACHARTSHOWNINFIG1INTHISCHART,THEPARAMETERSABOVETHEHORIZONTALDASHEDLINESARECONSIDEREDASFACTORSORINPUTSTOTHEHARDTURNINGPROCESSANDTHEYCANONLYBESELECTEDINTHEBEGINNINGEXCEPTTOOLVIBRATIONALLOTHERPARAMETERS,THATARELOCATEDBELOWTHESEDASHEDLINES,CONSIDEREDASPERFORMANCEMEASURESOROUTPUTSOFTHEHARDTURNINGPROCESSREVIEWOFTHELITERATUREREVEALSTHATALMOSTALLOFTHEFACTORSGIVENINTHISCHARTAFFECTPERFORMANCEOFTHEHARDTURNINGPROCESSTHOSEFACTORSCANBECLASSIFIEDASFOLLOWS11CUTTINGTOOLGEOMETRYANDMATERIALPROPERTIESHARDTURNINGWITHCBNCUTTINGTOOLSDEMANDSPRUDENTDESIGNOFTOOLGEOMETRYCBNCUTTINGTOOLSHAVELOWERTOUGHNESSTHANOTHERCOMMONTOOLMATERIALS,THUSCHIPPINGISMORELIKELY2THEREFORE,ANOSERADIUSANDPROPEREDGEPREPARATIONAREESSENTIALTOINCREASETHESTRENGTHOFCUTTINGEDGEANDATTAINFAVORABLESURFACECHARACTERISTICSONFINISHEDMETALCOMPONENTS23CBNCUTTINGTOOLSDESIGNEDFORHARDTURNINGFEATURENEGATIVERAKEGEOMETRYANDEDGEPREPARATIONACHAMFERORAHONE,OREVENBOTHSPECIFICATIONSOFTHEEDGEPREPARATIONDESIGNAREOFTENFINALIZEDAFTEREXTENSIVEEXPERIMENTATIONFIG2SHOWSTHETYPESOFEDGEPREPARATIONSCOMMONFORCBNCUTTINGTOOLSACCORDINGTORECENTSTUDIES,ITISEVIDENTTHATEFFECTOFEDGEGEOMETRYONSURFACEQUALITYISSIGNIFICANT2328FIG1AFLOWCHARTILLUSTRATINGRELATIONSHIPSOFFACTORSINHARDTURNINGTHEILEETAL24,25,PRESENTEDRESEARCHRESULTSOFANEXPERIMENTALINVESTIGATIONOFEFFECTSOFCUTTINGEDGEGEOMETRYANDWORKPIECEHARDNESSONRESIDUALSTRESSESINFINISHHARDTURNINGOFAISI52100STEELTHEYINDICATEDTHATBOTHFACTORSARESIGNIFICANTFORTHESURFACEINTEGRITYOFFINISHHARDTURNEDCOMPONENTSSPECIFICALLY,THEYSHOWEDTHATLARGEHONERADIUSTOOLSPRODUCEMORECOMPRESSIVESTRESSES,BUTALSOLEAVE“WHITELAYERS”ZEL26INVESTIGATEDTHEINFLUENCEOFEDGEGEOMETRYINCBNTOOLSWITHRESPECTTOSTRESSANDTEMPERATUREDEVELOPMENTTHROUGHFINITEELEMENTSIMULATIONSINHARDTURNINGCHOUETAL28EXPERIMENTALLYINVESTIGATEDTHEINFLUENCEOFCBNCONTENTONSURFACEQUALITYANDTOOLWEARINHARDENEDAISI52100STEELTOOLTHISSTUDYCONCLUDEDTHATLOWCONTENTCBNTOOLSPRODUCEBETTERSURFACEROUGHNESSWITHRESPECTTOHIGHERCONTENTCBNTOOLSANDDEPTHOFCUTHASMINOREFFECTONTOOLWEARRATEFIG2TYPEOFEDGEPREPARATIONSFORCBNCUTTINGTOOLS12WORKPIECEHARDNESSDUETOTHECHANGESINPROPERTIESOFHARDENEDWORKPIECEMATERIAL,BASICSHEARINGPROCESSANDFORMATIONOFCHIPSDIFFERINHARDTURNING5PRIORRESEARCHSHOWEDTHATWORKPIECEHARDNESSHASAPROFOUNDEFFECTONTHEPERFORMANCEOFTHECBNTOOLS1,2,8ANDALSOINTEGRITYOFFINISHMACHINEDSURFACES23,25MATSUMOTOETAL23ANDTHIELEETAL25STUDIEDTHEEFFECTOFWORKPIECEHARDNESSONRESIDUALSTRESSESINARECENTSTUDY,GUOANDLIU27INVESTIGATEDMATERIALPROPERTIESOFHARDENEDAISI52100BEARINGSTEELUSINGTEMPERATURECONTROLLEDTENSILETESTSANDORTHOGONALCUTTINGTESTSANDDEMONSTRATEDTHATHARDNESSGREATLYINFLUENCESTHEMATERIALPROPERTIESACCOUNTINGFORHIGHVARIATIONINFLOWSTRESSPROPERTIES13CUTTINGSPEED,FEEDRATEANDDEPTHOFCUTPERFORMANCEOFCBNCUTTINGTOOLSISHIGHLYDEPENDENTONTHECUTTINGCONDITIONSIECUTTINGSPEED,FEED,FEEDRATE,ANDDEPTHOFCUT7ESPECIALLYCUTTINGSPEEDANDDEPTHOFCUTSIGNIFICANTLYINFLUENCETOOLLIFE22INCREASEDCUTTINGSPEEDANDDEPTHOFCUTRESULTININCREASEDTEMPERATURESATTHECUTTINGZONESINCECBNISACERAMICMATERIAL,ATELEVATEDTEMPERATURESCHEMICALWEARBECOMESALEADINGWEARMECHANISMANDOFTENACCELERATESWEAKENINGOFCUTTINGEDGE,RESULTINGINPREMATURETOOLFAILURECHIPPING,NAMELYEDGEBREAKAGEOFTHECUTTINGTOOLINADDITION,THIELEETAL24NOTICEDTHATWHENFEEDRATEISINCREASED,RESIDUALSTRESSESCHANGEFROMCOMPRESSIVETOTENSILE14SURFACEINTEGRITY,RESIDUALSTRESSESANDTOOLWEARINGENERAL,RESIDUALSTRESSESBECOMEMORECOMPRESSIVEASWORKPIECEHARDNESSINCREASESTHEHARDNESSANDFRACTURETOUGHNESSOFCBNTOOLSDECREASEWITHREDUCEDCBNCONTENT8OWINGTOCERAMICBINDERPHASE,CBNLTOOLSHAVEALOWERTHERMALCONDUCTIVITY,WHICHCAUSESINCREASINGTEMPERATURESOFCUTTINGEDGEDURINGHARDTURNINGCHOUANDBARASH9REPORTEDTHATCBNLTOOLSAREMORESUITABLEFORFINISHTURNINGOFHARDENEDSTEELATLOWCUTTINGSPEEDS,TOOLLIFEOFCBNLISSUPERIORTOCBNH,WHEREASATHIGHERCUTTINGSPEEDS,THEREVERSEISTRUE,ANDALSOSURFACEROUGHNESSISLESSFAVORABLEWHENUSINGCBNHTOOL28THIELEETAL24REPORTEDTHATRESIDUALSTRESSESGENERATEDBYLARGEEDGEHONETOOLSARETYPICALLYMORECOMPRESSIVETHANSTRESSESPRODUCEDBYSMALLEDGEHONETOOLSANDTHEYALSOLEAVEWHITELAYERSINADDITION,THEEFFECTSOFEDGEGEOMETRYPLAYANIMPORTANTROLEINTHERMOPLASTICDEFORMATIONOFTHEWORKPIECEKOENIGETAL3REPORTEDTHATANINCREASEINFEEDRATERAISESTHECOMPRESSIVERESIDUALSTRESSMAXIMALANDDEEPENSTHEAFFECTEDZONEITWASALSOSUGGESTEDTHATTHECHAMFERISUNFAVORABLEINTERMSOFATTAINABLESURFACEFINISHWHENCOMPAREDTOHONEDORSHARPEDGES15ACCURACYANDRIGIDITYOFTHEMACHINETOOLANOTHERPARAMETERTHATISOFTENIGNOREDISTOOLVIBRATIONINORDERTOREDUCETOOLVIBRATIONITISNECESSARYPROVIDESUFFICIENTLYRIGIDTOOLANDWORKPIECEFIXTURESASSURINGTHATTHEREISMINIMALTOOLVIBRATIONISANEASYWAYTOIMPROVESURFACEROUGHNESSITISALSONECESSARYTHATTHETOOLINGSYSTEMBEEXTREMELYRIGIDTOWITHSTANDTHEIMMENSECUTTINGFORCESITISWELLKNOWNTHATTHERADIALFORCEISTHELARGESTAMONGFORCECOMPONENTSDURINGHARDTURNINGMANYRESEARCHERSINDICATEDTHATEXTREMELYRIGID,HIGHPOWER,ANDHIGHPRECISIONMACHINETOOLSAREREQUIREDFORHARDTURNINGBECAUSECBNTOOLSAREBRITTLEANDPRONETOCHIPPING3,7,8,14,23ITISALSOSUGGESTEDTHATHAVINGHIGHERRIGIDITYINMACHINETOOLCLAMPINGTOOLINGSYSTEMACHIEVESBETTERSURFACEQUALITYONTHEPARTITISWELLKNOWNTHATVIBRATIONANDCHATTERAREIMPORTANTPROBLEMSTHATDEGRADEPARTQUALITYANDTOOLPERFORMANCETOIMPROVETHEOVERALLEFFICIENCYOFFINISHHARDTURNING,ITISNECESSARYTOHAVEACOMPLETEPROCESSUNDERSTANDINGTOTHISEND,AGREATDEALOFRESEARCHHASBEENPERFORMEDINORDERTOQUANTIFYTHEEFFECTOFVARIOUSHARDTURNINGPROCESSPARAMETERSTOSURFACEQUALITYINORDERTOGAINAGREATERUNDERSTANDINGOFTHEHARDTURNINGPROCESSITISNECESSARYTOUNDERSTANDTHEIMPACTOFEACHOFTHESEVARIABLES,BUTALSOTHEINTERACTIONSBETWEENTHEMITISIMPOSSIBLETOFINDALLOFTHEVARIABLESTHATIMPACTSURFACEQUALITYINFINISHHARDTURNINGINADDITION,ITISCOSTLYANDTIMECONSUMINGTODISCERNTHEEFFECTOFEVERYVARIABLEONTHEOUTPUT2EXPERIMENTALPROCEDURE21WORKPIECEMATERIALTHEWORKPIECEMATERIALUSEDINTHISSTUDYWASAISIH13HOTWORKTOOLSTEEL,WHICHISUSEDFORHIGHDEMANDTOOLINGTHECYLINDRICALBARAISIH13SPECIMENTHATAREUTILIZEDINTHISEXPERIMENTSHADADIAMETEROF125INCHESANDLENGTHOF2FEETTHEBARSPECIMENSWEREHEATTREATEDTHROUGHHARDENEDATINHOUSEHEATTREATMENTFACILITYINORDERTOOBTAINTHEDESIREDHARDNESSVALUESOF50AND55HRCHOWEVER,THESUBSEQUENTHARDNESSTESTSBYUSINGFUTURETECHROCKWELLTYPEHARDNESSTESTERREVEALEDTHATTHEACTUALHARDNESSOFEACHSPECIMENWAS51310AND54705HRCHENCEFORTH,THEHARDNESSVALUESAREDEFINEDBYTHEMEANVALUESOFTHEMEASUREDWORKPIECEHARDNESS22TOOLINGANDEDGEGEOMETRYCBNINSERTSWITHTWODISTINCTREPRESENTATIVETYPESOFEDGEPREPARATIONSWEREINVESTIGATEDINTHISSTUDYTHESEEDGEPREPARATIONSINCLUDEA“CHAMFERED”TLANDEDGESANDB“HONED”EDGESASILLUSTRATEDINFIG2SOLIDTOPCBNINSERTSTNM433ANDGESUPERABRASIVESBZN8100GRADEINSERTSWEREUSEDWITHAKENNAMETALDTGNR124BRIGHTHANDTOOLHOLDERWITH00LEADAND50RAKEANGLESHONEDANDCHAMFEREDINSERTEDGEGEOMETRYWEREMEASUREDINCOORDINATEDMEASUREMENTMACHINEWITHTHREEREPLICATIONSUSINGAHIGHPRECISIONTOUCHTRIGGERPROBEFORTHEHONEDINSERTS,ANAVERAGERADIUSOF10540MWASFOUNDCHAMFEREDINSERTEDGEGEOMETRYWASFOUNDTOHAVE200CHAMFERANGLEAND01003MMCHAMFERWIDTHUSINGSAMEINSTRUMENTSWITHTHREEREPLICATIONSANDWASAPPROXIMATEDTOANEQUIVALENTHONERADIUSOF101651M23EXPERIMENTALDESIGNAFOURFACTORTWOLEVELFACTORIALDESIGNWASUSEDTODETERMINETHEEFFECTSOFTHECUTTINGEDGEGEOMETRY,WORKPIECEHARDNESS,FEEDRATEANDCUTTINGSPEEDONSURFACEROUGHNESSANDRESULTANTFORCESINTHEFINISHHARDTURNINGOFAISIH13STEELTHEFACTORSANDFACTORLEVELSARESUMMARIZEDINTABLE1THESEFACTORLEVELSRESULTSINATOTALOF16UNIQUEFACTORLEVELCOMBINATIONSSIXTEENREPLICATIONSOFEACHFACTORLEVELCOMBINATIONSWERECONDUCTEDRESULTINGINATOTALOF256TESTSEACHREPLICATIONREPRESENTS254MMCUTTINGLENGTHINAXIALDIRECTIONTHERESPONSEVARIABLESARETHEWORKPIECESURFACEROUGHNESSANDTHECUTTINGFORCESLONGITUDINALTURNINGWASCONDUCTEDONARIGID,HIGHPRECISIONCNCLATHEROMICENTUR35EATACONSTANTDEPTHOFCUTAT0254MMTHEBARWORKPIECESWEREHELDINTHEMACHINEWITHACOLLETTOMINIMIZERUNOUTANDMAXIMIZERIGIDITYTHELENGTHOFCUTFOREACHTESTWAS254MMINTHEAXIALDIRECTIONDUETOAVAILABILITYCONSTRAINTS,EACHINSERTWEREUSEDFORONEFACTORLEVELCOMBINATION,WHICHCONSISTEDOF16REPLICATIONSATOTALOFTHREEHONEDANDTHREECHAMFERINSERTSWEREAVAILABLEINTHISMANNEREACHEDGEPREPARATIONWASSUBJECTTOTHESAMENUMBEROFTESTSANDTHESAMEAXIALLENGTHOFCUTFINALLY,SURFACEROUGHNESSANDTOOLWEARMEASUREMENTSWERECONDUCTEDWHENTHECUTTINGLENGTHREACHED2032MM8INCHESAND4064MM16INCHESDURINGEACHFACTORLEVELCOMBINATIONTHESURFACEROUGHNESSWASMEASUREDWITHATAYLORHABSONSURTRONIC3PROFILOMETERANDMITUTOYOSJDIGITALSURFACEANALYZER,USINGATRACELENGTHOF48MM,ACUTOFFLENGTHOF08MMTHESURFACEROUGHNESSVALUESWERERECORDEDATEIGHTEQUALLYSPACEDLOCATIONSAROUNDTHECIRCUMFERENCEEVERY254MMDISTANCEFROMTHEEDGEOFTHESPECIMENTOOBTAINSTATISTICALLYMEANINGFULDATAFOREACHFACTORLEVELCOMBINATIONCBNINSERTSWEREEXAMINEDUSINGATOOLMAKERMICROSCOPETOMEASUREFLANKWEARDEPTHANDDETECTUNDESIRABLEFEATURESONTHEEDGEOFTHECUTTINGTOOLBYINTERRUPTINGFINISHHARDTURNINGPROCESS24CUTTINGFORCEMEASUREMENTSTHECUTTINGFORCESWEREMEASUREDWITHATHREECOMPONENTFORCEDYNAMOMETERKISTLERTYPE9121MOUNTONTHETURRETDISKOFTHECNCLATHEVIAACUSTOMDESIGNEDTURRETADAPTERKISTLERTYPE9121FORTHETOOLHOLDERCREATINGAVERYRIGIDTOOLINGFIXTURETHECHARGESIGNALGENERATEDATTHEDYNAMOMETERWASAMPLIFIEDUSINGCHARGEAMPLIFIERSKISTLERTYPE5814B1THEAMPLIFIEDSIGNALISACQUIREDANDSAMPLEDBYUSINGDATAACQUISITIONPCMCIACARDANDKISTLERDYANOWARESOFTWAREONALAPTOPCOMPUTERATASAMPLINGFREQUENCYOF2000HZPERCHANNELTIMESERIESPROFILESOFTHEACQUIREDFORCEDATAREVEALTHATTHEFORCESARERELATIVELYCONSTANTOVERTHELENGTHOFCUTANDFACTORSSUCHASVIBRATIONANDSPINDLERUNOUTWERENEGLIGIBLETHREECOMPONENTSOFTHERESULTANTFORCEARESHOWNSCHEMATICALLYINFIG3FIG3MEASUREDCUTTINGFORCECOMPONENTS3RESULTSANDDISCUSSIONANANALYSISOFVARIANCEANOVAWASCONDUCTEDTOIDENTIFYSTATISTICALLYSIGNIFICANTTRENDSINTHEMEASUREDSURFACEROUGHNESSANDCUTTINGFORCEDATASEPARATEANOVAANALYSESWERECONDUCTEDFORRASURFACEROUGHNESSVALUESANDFOREACHCOMPONENTOFTHECUTTINGFORCEIEAXIALFEED,RADIALTHRUST,ANDTANGENTIALCUTTINGFORCESADDITIONALLY,PLOTSOFSIGNIFICANTFACTORSCORRESPONDINGTOEACHANOVAANALYSISWERECONSTRUCTEDTHESEPLOTSPROVIDEAMOREINDEPTHANALYSISOFTHESIGNIFICANTFACTORSRELATEDTOTHESURFACEROUGHNESSANDCUTTINGFORCESINFINISHHARDTURNINGOFAISIH13STEELUSINGCHAMFEREDANDHONEDCBNINSERTS31ANOVARESULTSANOVATABLESFORRASURFACEROUGHNESSPARAMETERSAREGIVENINTABLE2INADDITIONTODEGREEOFFREEDOMDF,MEANSQUAREMSANDFVALUESFTHETABLESHOWSTHEPVALUESPASSOCIATEWITHEACHFACTORLEVELANDINTERACTIONALOWPVALUEINDICATESANINDICATIONOFSTATISTICALSIGNIFICANGEFORTHESOURCEONTHERESPONSETABLE2SHOWTHATTHEMAINEFFECTSOFEDGEGEOMETRY,CUTTINGSPEEDANDFEEDRATEEXCEPTHARDNESS,INTERACTIONSBETWEENEDGEGEOMETRYANDHARDNESS,FEEDRATE,ANDCUTTINGSPEED,THEINTERACTIONSBETWEENCUTTINGSPEEDANDFEEDRATEARESIGNIFICANTTOSURFACEROUGHNESSFEEDRATEISTHEDOMINANTPARAMETERASSOCIATEDWITHTHESURFACEROUGHNESSTHISISEXPECTEDBECAUSEITISWELLKNOWNTHATTHETHEORETICALSURFACEROUGHNESSISPRIMARILYAFUNCTIONOFTHEFEEDFORAGIVENNOSERADIUSANDVARIESASTHESQUAREOFTHEFEEDRATE8THERADIALFORCEISUSUALLYTHELARGEST,TANGENTIALFORCEISTHEMIDDLEANDTHEAXIALFEEDFORCEISTHESMALLESTINFINISHHARDTURNINGINGENERAL,CUTTINGFORCECOMPONENTSAREINFLUENCESBYCUTTINGSPEED,EDGEGEOMETRYANDFEEDRATETABLES35AREANOVATABLESCORRESPONDINGTOTHERADIAL,AXIALFEEDFORCEANDTANGENTIALCOMPONENTSOFTHECUTTINGFORCE,RESPECTIVELYTHESETABLESSHOWTHATTHEMAINEFFECTSOFWORKPIECEHARDNESS,THEEDGEGEOMETRY,CUTTINGSPEEDANDFEEDRATEEXCEPTFORAXIALFORCEAREALLSIGNIFICANTWITHRESPECTTOTHEFORCESINTHERADIAL,AXIALANDTANGENTIALDIRECTIONSTABLE3SHOWSTHATTHEMAINEFFECTSOFTHEEDGEGEOMETRY,CUTTINGSPEED,HARDNESSANDTHEINTERACTIONSBETWEENEDGEGEOMETRYANDHARDNESS,CUTTINGSPEED,FEEDRATEARESIGNIFICANTWITHRESPECTTOTHEFORCESINTHEAXIALFEEDDIRECTIONAXIALFEEDFORCEISNOTMUCHINFLUENCEBYTHECHANGEINFEEDRATETABLE4SHOWSTHATTHEMAINEFFECTSOFTHEEDGEGEOMETRY,CUTTINGSPEED,HARDNESSANDONLYTHEINTERACTIONSBETWEENEDGEGEOMETRYANDCUTTINGSPEED,FEEDRATEARESIGNIFICANTWITHRESPECTTOTHEFORCESINTHERADIALDIRECTIONTABLE5SHOWSTHATTHEMAINEFFECTSOFTHEEDGEGEOMETRY,CUTTINGSPEED,HARDNESS,FEEDANDONLYTHEINTERACTIONSBETWEENEDGEGEOMETRYANDHARDNESS,CUTTINGSPEED,FEEDRATEARESIGNIFICANTWITHRESPECTTOTHEFORCESINTHETANGENTIALDIRECTION32EFFECTOFFEEDRATEANDEDGEPREPARATIONONSURFACEROUGHNESSGRAPHSOFRASURFACEROUGHNESSPARAMETERSARESHOWNINFIGURES4AND5THESEFIGURESHAVEBEENCONSTRUCTEDTOILLUSTRATETHEMAINEFFECTSOFEDGEGEOMETRYANDFEEDRATEPARAMETERSONTHESURFACEROUGHNESSBASEDONTHEPREVIOUSANALYSIS,THEMAINEFFECTOFTHEINTERACTIONBETWEENEDGEGEOMETRYANDFEEDRATEAREFOUNDTOBESTATISTICALLYSIGNIFICANTONSURFACEROUGHNESSRAFIG4SHOWSTHEEFFECTOFEDGEGEOMETRYANDFEEDRATEONTHERASURFACEROUGHNESSPARAMETERFOR547HRC,CUTTINGSPEED200M/MINANDCUTTINGLENGTHOF4064MMFIG5SHOWSTHEEFFECTOFEDGEGEOMETRYANDFEEDRATEONTHERASURFACEROUGHNESSPARAMETERFOR513HRCWITHCUTTINGSPEEDOF100M/MINANDCUTTINGLENGTHOF254MMFIG4EFFECTOFCUTTINGEDGEGEOMETRYANDFEEDRATEONSURFACEROUGHNESSHIGHLEVELSFIG5EFFECTOFCUTTINGEDGEGEOMETRYANDFEEDONSURFACEROUGHNESSLOWLEVELSTHESETWOFIGURESSHOWTHATALLEDGEPREPARATIONSARECONFOUNDEDATTHELOWESTFEEDRATE005MM/REVHOWEVER,THELARGEEDGERADIUSRESULTEDINBETTERSURFACEROUGHNESSWHENHIGHERHARDNESSANDCUTTINGSPEEDSELECTED,WHEREASITISTHEOPPOSITEWHENLOWERHARDNESSANDCUTTINGSPEEDSELECTEDFINALLY,ITSHOULDBENOTEDTHATTHEMAINEFFECTDUETOFEEDISREADILYAPPARENTFOREACHEDGEPREPARATIONSPECIFICALLY,THESURFACEROUGHNESSINCREASESASTHEFEEDRATEINCREASESASTHESURFACEROUGHNESSBEINGPROPORTIONALTOTHESQUAREOFTHEFEEDRATE33EFFECTOFSURFACEHARDNESSANDEDGEPREPARATIONONSURFACEROUGHNESSFIG6ISCONSTRUCTEDTOILLUSTRATETHEMAINEFFECTSOFEDGEGEOMETRYANDSURFACEHARDNESSPARAMETERSONTHESURFACEROUGHNESSWITHCUTTINGSPEED200M/MIN,FEEDRATE02MM/REVANDCUTTINGLENGTH4064MMBASEDONTHEPREVIOUSANALYSIS,THEMAINEFFECTOFTHEINTERACTIONBETWEENEDGEGEOMETRYANDWORKPIECESURFACEHARDNESSARESTATISTICALLYSIGNIFICANTTOSURFACEROUGHNESSRAPARAMETERSTHEFIGURESHOWSTHATSMALLEDGERADIUSANDLOWERWORKPIECESURFACEHARDNESSRESULTEDINBETTERSURFACEROUGHNESSFIG6EFFECTOFCUTTINGEDGEGEOMETRYANDHARDNESSONSURFACEROUGHNESS34EFFECTOFSURFACEHARDNESSANDEDGEPREPARATIONONTANGENTIAL,RADIALANDAXIALFEEDFORCESGRAPHSOFTHEFORCECOMPONENTSASFUNCTIONSOFEDGEGEOMETRYANDWORKPIECESURFACEHARDNESSARESHOWNINFIGS79THESEFIGURESSHOWTHATCHAMFEREDEDGEGEOMETRYANDHIGHERWORKPIECESURFACEHARDNESSRESULTINHIGHERTANGENTIALANDRADIALFORCESBUTNOTINAXIALFEEDFORCEADDITIONALLY,SMALLHONEDRADIUSEDGEGEOMETRYRESULTSINHIGHERFORCESINTHEAXIALFEEDDIRECTIONSFIG7EFFECTOFCUTTINGEDGEGEOMETRYANDSURFACEHARDNESSONTANGENTIALFORCEFIG8EFFECTOFCUTTINGEDGEGEOMETRYANDSURFACEHARDNESSONRADIALFORCEFIG9EFFECTOFCUTTINGEDGEGEOMETRYANDSURFACEHARDNESSONAXIALFORCE35EFFECTOFCUTTINGSPEEDANDCUTTINGEDGEGEOMETRYONTANGENTIALFORCEFIG10ISOBTAINEDTOILLUSTRATETHEMAINEFFECTSOFEDGEGEOMETRYANDCUTTINGSPEEDPARAMETERSONTANGENTIALFORCEBASEDONTHEPREVIOUSANALYSIS,THEMAINEFFECTOFTHEEDGEGEOMETRYANDCUTTINGSPEEDARESTATISTICALLYSIGNIFICANTTOTANGENTIALFORCEFIG10SHOWSTHATHIGHERCUTTINGSPEEDANDSMALLEREDGERADIUSRESULTEDINLOWERTANGENTIALFORCE36EFFECTOFCUTTINGSPEEDANDFEEDRATEONTANGENTIALFORCEFIG11ISOBTAINEDTOILLUSTRATETHEMAINEFFECTSOFCUTTINGSPEEDANDFEEDRATEPARAMETERSONTANGENTIALFORCEBASEDONTHEPREVIOUSANALYSIS,THEINTERACTIONOFCUTTINGSPEEDANDFEEDRATEARESTATISTICALLYSIGNIFICANTTOTANGENTIALFORCEFIG11SHOWSTHATLOWERCUTTINGSPEEDANDLOWERFEEDRATERESULTEDINLOWERTANGENTIALFORCEFIG10EFFECTOFCUTTINGSPEEDANDCUTTINGEDGEGEOMETRYONTANGENTIALFORCEFIG11EFFECTOFCUTTINGSPEEDANDFEEDRATEONTANGENTIALFORCE4CONCLUSIONSINTHISSTUDY,ADETAILEDEXPERIMENTALINVESTIGATIONISPRESENTEDFORTHEEFFECTSOFCUTTINGEDGEPREPARATIONGEOMETRY,WORKPIECESURFACEHARDNESSANDCUTTINGCONDITIONSONTHESURFACEROUGHNESSANDCUTTINGFORCESINTHEFINISHHARDTURNINGOFAISIH13STEELTHERESULTSHAVEINDICATEDTHATTHEEFFECTOFCUTTINGEDGEGEOMETRYONTHESURFACEROUGHNESSISREMARKABLYSIGNIFICANTTHECUTTINGFORCESAREINFLUENCEDBYNOTONLYCUTTINGCONDITIONSBUTALSOTHECUTTINGEDGEGEOMETRYANDWORKPIECESURFACEHARDNESSTHISSTUDYSHOWSTHATTHEEFFECTSOFWORKPIECEHARDNESS,CUTTINGEDGEGEOMETRY,FEEDRATEANDCUTTINGSPEEDONSURFACEROUGHNESSARESTATISTICALLYSIGNIFICANTTHEEFFECTSOFTWOFACTORINTERACTIONSOFTHEEDGEGEOMETRYANDTHEWORKPIECEHARDNESS,THEEDGEGEOMETRYANDTHEFEEDRATE,ANDTHECUTTINGSPEEDANDFEEDRATEAREALSOAPPEAREDTOBEIMPORTANTESPECIALLY,SMALLEDGERADIUSANDLOWERWORKPIECESURFACEHARDNESSRESULTEDINBETTERSURFACEROUGHNESSCUTTINGEDGEGEOMETRY,WORKPIECEHARDNESSANDCUTTINGSPEEDAREFOUNDTOBEAFF