High-performance circular sawing of AISI 1045 steel with cermet and tungsten carbide inserts
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DOI 10.1007/s12206-014-0941-5
High-performance circular sawing of AISI 1045 steel with cermet and tungsten carbide inserts† A. M. Abrão1,*, M. C. Moreira2, P. E. Faria2 and J. C. Campos Rubio1 1
Department of Mechanical Engineering, Universidade Federal de Minas Gerais, Av. Antônio Carlos, 6627, Pampulha, CEP 31270-901, Belo Horizonte, MG, Brazil 2 Department of Production Engineering, Universidade Federal de Minas Gerais, Av. Antônio Carlos, 6627, Pampulha, CEP 31270-901, Belo Horizonte, MG, Brazil (Manuscript Received September 12, 2013; Revised April 14, 2014; Accepted June 18, 2014) ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Abstract This work investigated the influence of cutting speed and feed rate on cutting forces, surface roughness, and slot width circular sawing of AISI 1045 steel. The effects of tool material (cermet and tungsten carbide) and geometry (chip breaker flute and pre-cutting/postcutting teeth) were also investigated. Thrust and radial forces generally tended to decrease as the cutting speed increased and tended to increase with the feed rate. The lowest values of thrust and radial forces were obtained using a tungsten carbide saw ground with precutting and post-cutting teeth. With regard to the quality of the machined wall, the lowest surface roughness was obtained by applying the highest cutting speed and lowest feed rate and employing a cermet brazed saw. Under this condition, roughness values comparable to face turning and parting off operations were obtained. The cermet brazed saw was responsible for producing the narrowest slot widths. Keywords: Cermet; Circular saw blade; Circular sawing; Rotary sawing; Tungsten carbide ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
1. Introduction Circular sawing is widely used in metal working companies to cut off long bars produced by forming operations (such as rolling and drawing) into smaller parts before they are subjected to machining operations. Klocke [1] reported that circular sawing is considered a high-performance process for straight cutting of preferably low-cost materials because of the wide kerf produced. Therefore, developing strategies to reduce kerf width and improve machined surface quality would allow cutting of nobler materials. Reducing kerf width and improving machined surface quality can be accomplished by using high-strength tools that are suitably ground with proper tensioning of the blade and stable sawing machines. High-speed steel is widely used for manufacturing circular saw blades. Tungsten carbide and cermet inserts brazed on a high-speed st
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