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Presentation of a novel cutting technology for precision machining of hardened, rotationally symmetric parts

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Abstract

In this paper a new cutting technology similar to hard turning is presented to cut rotationally symmetric parts made of hardened materials. This novel technology, which is named rotational turning, is based on a combination of hard turning and circular milling. An analytical model is developed to describe the engagement parameters between tool and workpiece. It is shown by the model, that the virtual tool corner radius in rotational turning, which takes effect during the cutting process, is more than 50 times larger than in state of the art hard turning. Due to this, feed marks, which are common in turning, can be reduced to a level, where they are not measurable anymore. It can be shown in experiments, that the minimum achievable surface roughness is therefore not limited by the feed rate anymore, like in turning processes usual, but by other effects like the waviness of the cutting edge.

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Abbreviations

agr :

Depth of grooves

ap :

Depth of cut

f:

Feed

fax :

Feed caused by axial tool movement

frot :

Feed caused by tool rotation

fvirt :

Virtual feed

h:

Pitch hight

hc :

Undeformed chip thickness

hcu :

Minimum undeformed chip thickness

l1 :

Workpiece length

l2 :

Tool length

lc :

Axial contact length

lrest :

Difference between tool and workpiece length

n1 :

Workpiece revolution

n2 :

Tool revolution

r1 :

Workpiece radius

r2 :

Tool radius

rgr :

Radius of the cutting grooves

rt :

Radius of the helix top

rvirt :

Virtual tool corner radius

rε :

Tool corner radius

Ra:

Average roughness

Rt:

Theoretical kinematic surface roughness

Rz:

Average roughness depth

t:

Time

tax :

Time for axial tool movement

trot :

Time for tool rotation

vax :

Axial tool velocity

vc :

Cutting velocity

vrot :

Axial velocity caused by tool rotation

VB:

Width of flank wear

α1 :

Workpiece contact angel

α2 :

Tool contact angel

λ:

Helix angle

λc:

Cut-off length

References

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Author information

Authors and Affiliations

  1. Fraunhofer Institute for Production Technology IPT, Aachen, Germany

    Fritz Klocke, Thomas Bergs, Florian Degen & Philipp Ganser

Authors
  1. Fritz Klocke
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  2. Thomas Bergs
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  3. Florian Degen
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  4. Philipp Ganser
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Corresponding author

Correspondence to Florian Degen.

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Klocke, F., Bergs, T., Degen, F. et al. Presentation of a novel cutting technology for precision machining of hardened, rotationally symmetric parts. Prod. Eng. Res. Devel. 7, 177–184 (2013). https://doi.org/10.1007/s11740-012-0438-y

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  • DOI: https://doi.org/10.1007/s11740-012-0438-y

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