Ultrafine particle emission during high-speed milling of hardened AISI 1045 steel
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ORIGINAL ARTICLE
Ultrafine particle emission during high-speed milling of hardened AISI 1045 steel Mohamed Shnfir 1 & J. Kouam 1 & V. Songmene 1 Received: 24 February 2020 / Accepted: 3 August 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract In this study, the effects of cutting speed, feed rate, and hardness of workpiece material on the particle number concentration ultrafine of particles in the face milling were experimentally investigated. AISI 1045 steel was hardened to 17, 38, and 48 HRC, machining using ceramic insert (honed, T-land edge preparation). Three factors (cutting speed, feed rate, and workpiece hardness) and three levels fractional experiment designs completed (L27) with statistical analysis of variance (ANOVA) were performed. The analysis of the results shows that workpiece hardness has the greatest influence on ultrafine particle (UFP) emission for both tools and that the feed rate and the cutting speed should be selected wisely for each tool edge preparation. Overall, it is shown that the use of honed edge at moderate speed and higher feed rate reduces UFP emission during milling. Keywords AISI 1045 steel . Face milling . Ceramic Inserts . Tool edge preparation . Ultrafine particle emission
1 Introduction Ceramic cutting tools is the one of most cutting tool used for machining super alloys and hard materials during the high speed due to their distinctive mechanical properties. Ceramics have high melting point, excellent hardness, and good wear resistance and chemical stability inactivity [1, 2]. Several researchers [3–16] have conducted research works on the performance of ceramic tools when machining hard materials, and they have shown that the surface roughness, the cutting forces, and tool wear are dependent on cutting condition and tool geometry. In manufacturing industries, dry cutting have been widely applied due to its assistance on increasing * V. Songmene [email protected] Mohamed Shnfir [email protected] J. Kouam [email protected] 1
Department of Mechanical Engineering, École de Technologie Supérieure (ÉTS), 1100 Notre-Dame St. West, Montréal, QC H3C 1K3, Canada
productivity, decreasing air pollution, and decreasing machining costs [17–21]. In the dry machining, cutting tool life is short and that is a main problem when machining hardened materials. Ceramic tool inserts and carbides (coated by TiN, TiC) are recommended for dry machining [22–24]. During dry cutting processes of hardened steels, the alumina (Al2O3)-based ceramic is one the most recommended tool material because it has high hot hardness and good resistance to wear and chemical stability inactivity. For improved performance, they are commonly reinforced with Ti(C, N) and ZrO2 additions [3, 7, 25, 26]. Dry cutting processes produce clean chips that are easy to recycle [27–29]. However, metallic particles emitted can deteriorate the working environments and the machine tool operators’ health [30–32]. The machine tool operators are exposed to dust particles through inhalation, and
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