Next Article in Journal
Comparative Surface Morphology, Chemical Composition, and Cytocompatibility of Bio-C Repair, Biodentine, and ProRoot MTA on hDPCs
Next Article in Special Issue
Evaluation of Surface Topography after Face Turning of CoCr Alloys Fabricated by Casting and Selective Laser Melting
Previous Article in Journal
Microstructure and Degradation of Mortar Containing Waste Glass Aggregate as Evaluated by Various Microscopic Techniques
Previous Article in Special Issue
Increasing Damping of Thin-Walled Structures Using Additively Manufactured Vibration Eliminators
 
 
Search for Articles:
Title / Keyword
Author / Affiliation / Email
Journal
Article Type
 
 
Advanced Search
 
Section
Special Issue
Volume
Issue
Number
Page
 
Journals
Materials
Volume 13
Issue 9
10.3390/ma13092188
materials-logo
Submit to this Journal Review for this Journal Propose a Special Issue
► Article Menu

Article Menu

share Share announcement Help format_quote Cite question_answer Discuss in SciProfiles thumb_up
...
Endorse textsms
...
Comment
first_page
settings
Order Article Reprints
Font Type:
Arial Georgia Verdana
Font Size:
Aa Aa Aa
Line Spacing:
Column Width:
Background:
Article

On the Chip Shaping and Surface Topography When Finish Cutting 17-4 PH Precipitation-Hardening Stainless Steel under Near-Dry Cutting Conditions

by
Kamil Leksycki
1,
Eugene Feldshtein
1,
Grzegorz M. Królczyk
2 and
Stanisław Legutko
3,*
1
Institute of Mechanical Engineering, University of Zielona Gora, 4 Prof. Z. Szafrana Street, 65-516 Zielona Gora, Poland
2
Department of Manufacturing Engineering and Production Automation, Opole University of Technology, 76, Proszkowska Street, 45-758 Opole, Poland
3
Faculty of Mechanical Engineering, Poznan University of Technology, 3 Piotrowo Street, 60-965 Poznan, Poland
*
Author to whom correspondence should be addressed.
Materials 2020, 13(9), 2188; https://doi.org/10.3390/ma13092188
Submission received: 8 April 2020 / Revised: 1 May 2020 / Accepted: 6 May 2020 / Published: 9 May 2020
(This article belongs to the Special Issue Precision and Ultra-Precision Subtractive and Additive Manufacturing Processes of Alloys and Steels)
Browse Figures
Review Reports Versions Notes

Abstract

:
This study describes the surface topography of the 17-4 PH stainless steel machined under dry, wet and near-dry cutting conditions. Cutting speeds of 150–500 m/min, feeds of 0.05–0.4 mm/rev and 0.5 mm depth of cutting were applied. The research was based on the ‘parameter space investigation’ method. Surface roughness parameters, contour maps and material participation curves were analysed using the optical Sensofar S Neox 3D profilometer and the effect of feed, cutting speed and their mutual interaction was noticed. Changes in chip shape depending on the processing conditions are shown. Compared to dry machining, a reduction of Sa, Sq and Sz parameters of 38–48% was achieved for near-dry condition. For lower feeds and average cutting speeds valleys and ridges were observed on the surface machined under dry, wet and near-dry conditions. For higher feeds and middle and higher cutting speeds, deep valleys and high ridges were observed on the surface. Depending on the processing conditions, different textures of the machined surface were registered, particularly anisotropic mixed, periodic and periodically determined. In the Sa range of 0.4–0.8 μm for dry and wet conditions the surface isotropy is ~20%, under near-dry conditions it is ~60%.

1. Introduction

The 17-4 PH steel is a relatively new and increasingly popular stainless material for medical devices [1,2]. In particular, it is widely used in the production of surgical instruments [1,3] and orthopaedic instruments [4].
The chip shape is the result of physical-chemical phenomena occurring in the cutting zone and plays a significant role in the cutting process and the quality of the surface machined. The chip may occupy a volume many times greater than the material from which it was made and may also cause difficulties in its removal from the machining zone [5]. When turning, the cutting edge of the insert is in constant contact with the material being machined, which usually leads forming of long and snarling chips. This chip often wounds around the cutting tool and causes abrasions on the machined surface [6]. Therefore, the use of machining fluids in the cutting process is an important factor influencing the appropriate chip formation and effective removal from the cutting zone [7,8]. One of the main factors determining the effectiveness of the materials use is the topography of machined surface [9]. It has a significant impact on the operating properties of biomedical materials parts, particularly on wear and corrosion resistance [10]. When turning, one of the factors influencing the surface topography is the type of cooling lubricant used, which is also very important for environmental and human health risks [11].
Therefore, current scientific research is focused on the search for improvements in machining processes for sustainable clean production, including minimizing the use of cooling lubricants and improving surface quality [12,13].
Pereira et al. [14] tested the combination of cryogenic and minimum quantity lubrication (MQL) methods while carrying out the ecological processing of the AISI 304 stainless steel. The better results in comparison with other cooling methods were ensured. Zou et al. [15] analysed the roughness and surface topography of the 17-4 PH steel under different processing conditions. The cryogenic cooling provided more favourable results. Sivaiah and Chakradhar [16] examined the cryogenic machining of the 17-4 PH steel. It was found that in comparison to wet cooling, cryogenic cooling reduces surface roughness. Sivaiah and Chakradhar [17] studied the influence of liquid N2 cooling when cutting the 17-4 PH steel in comparison with other cooling conditions. At each cutting depth cryogenic turning reduced surface roughness and improved surface integrity in comparison with other methods. Leksycki and Feldshtein [18] investigated the formation of surface texture of the 17-4PH (X5CrNiCuNb16-4) steel under dry and wet turning. In comparison with dry processing, the reduction of roughness parameters about 30% was registered during wet turning. Jerold and Kumar [19] tested the CO2 effect as a cooling medium on the surface roughness when cutting the 316 steel. The results were compared with other cooling methods and revealed that CO2 increased the surface integrity in the range of 4–52%. Krolczyk et al. [20] presented different images of the surface topography of the 1.4462 steel after dry and minimum quantity cooling lubrication (MQCL) turning. Compared to dry machining, the 3D surface texture parameters were reduced under MQLC conditions when using higher cutting parameters. In comparison to dry machining, a more favourable surface was obtained under MQCL conditions. Maruda et al. [21] tested the effect of different near-dry cutting conditions on Ra and Rq values of the 1.4310 (X10CrNi18-8) steel. It was observed that in comparison with dry cutting near-dry cutting causes a decrease in the roughness parameters from 2% to 42%. Rajaguru and Arunachalam [22] tested the impact of cooling conditions on the topography and surface roughness profiles of a super duplex steel. MQL machining provided better results. Elmunafi et al. [23] evaluated the effectiveness of MQL machining with a castor oil when turning the AISI 420 steel. Compared to dry machining conditions, the MQL conditions resulted in a better tool life, but a slight increase of the surface roughness was observed.
Summarizing, it can be said that in the current state of knowledge the possibilities of modern near-dry cutting methods in the machining of stainless steels are presented quite extensively, however, there is a lack of analysis of the chip shaping and three dimensional surface topography of modern precipitation-hardening (PH) steels. The main aim of this research is the comparison of different near-dry conditions efficiencies on the chip shaping and surface texture after finish cutting of the 17-4 PH steel.

2. Materials and Methods

The 17-4 PH (AISI 630) steel was machined, whose chemical composition and mechanical properties correspond to ASTM A693 Grade 630 standard.
The 17-4 PH steel is precipitation-hardening chromium-nickel steel with a martensitic structure containing a small volume of austenite. The steel contains copper (about 3%) and is reinforced with copper-rich particulates because of their precipitation from the metal matrix [24,25]. According to DIN EN 10088-1:2014-12, the material has a modulus of elasticity of 195 GPa, a tensile strength of 930–1100 MPa and a yield strength of 720 MPa. The steel has the excellent corrosion resistance in comparison with typical 304 or 316L stainless steels [2], while it has low thermal conductivity, which reduces the machinability and negatively affects the surface quality and the life of cutter [26].
The tests were carried out using the CTX 510 machining centre (DMG MORI, Pleszew, Poland). A turning tool was used with CoroTurn SDJCR 2525M 11 tool holder (Sandvik Coromant, Sandviken, Sweden) and CoroTurn DCMX 11 T3 04-WM 1115 insert (Sandvik Coromant, Sandviken, Sweden). The cutting material was GC 1115 cemented carbide (group S according to ISO 513:2012 standard) with PVD coating.
Turning was performed with cutting speeds vc = 150–500 m/min, feeds f = 0.05–0.4 mm/rev with the 0.5 mm depth of cutting that corresponds with the finish machining conditions. The machining was carried out using samples with the length of 15 mm the diameter of 50 mm. Three measurements were made for each surface treated.
Following cooling conditions were applied: dry, wet, minimum quantity lubrication (MQL) and MQL with extreme pressure (EP) addition (extreme pressure additive based on phosphorus ester). EP additive is usually added to protect the surface against wear [27,28]. A water emulsion of Castrol Alusol SL 51 XBB emulsifying oil with 7% concentration was used as a cutting fluid. Oil mist was produced as a mixture of air and ECOCUT MIKRO 20 E oil. Phosphorus ester was used as an extreme pressure additive. Such additives are used to decrease wear of the parts that work under very high pressures. They are also added to cutting fluids for machining of metals.
Lenox 1LN Micronizer (Lenox, East Longmeadow, MA, USA) was used to generate oil mist. Constant air and oil flows as well as constant air pressure were applied, which ensure the best conditions for mist production [28,29].
Topography parameters of the surface of the machined steel were measured with the use of Sensofar S Neox 3D optical profilometer (Sensofar Group, Barcelona, Spain) using Confocal Profilers technology. The measurement results were prepared using Mountains Maps Premium 7.4 software (Digital Surf, Besançon, France).
The parameters of the surface texture are used primarily for a quantitative assessment of the condition of the surface analysed [5,30]. Texture parameters include, inter alia, amplitude parameters, and the most important of them according to ISO 25178-2:2012 are Sa, Sq and Sz. From a statistical point of view, Sa is interpreted as the arithmetic mean height deviation of the texture elements within the sampling area, Sq determines the square mean deviation of this elements and Sz defines the maximum height of the vertices within the sampling area.
Statistical analysis of measurements was carried out using the Statistica 13 software (StatSoft, Kraków, Poland).
The plan of investigations was developed based on the method named ‘parameter space investigation’ (PSI) that allows planning experiments while minimizing the number of research points [31]. The research points are located in a multidimensional space so that their projections on the X1 and X2 axes are equally spaced to each other (Figure 1). Point coordinates in the range of Xmin = 0 and Xmax = 1 are presented in Table 1.

3. Results and Discussion

3.1. Chip Shaping

Chip shapes after finishing turning under cooling conditions tested are shown in Figure 2 for minimum surface roughness (vc~280 m/min and f~0.094 mm/rev), medium surface roughness (vc~456 m/min and f~0.27 mm/rev) and maximum surface roughness (vc~194 m/min and f~0.36 mm/rev).
When turning with vc~280 m/min and f~0.094 mm/rev, long and snarling chips were recorded under the cooling conditions tested. Michailidis [32] found that such chips can entangle a cutting tool, leading to its faster wear and at the same time drawing the machined surface.
When turning with vc~456 m/min and f~0.27 mm/rev, short spiral chips can be observed for all investigated cooling conditions, which is desirable for industrial use.
When turning with vc~194 m/min and f~0.36 mm/rev under dry, wet and MQL machining conditions, long spiral chips were obtained and for machining with MQL+EP long screwed chips were observed.

3.2. The Turning Conditions Influence on the Surface Texture Amplitude Parameters

The software used made it possible to determine statistical models (Table 2) and graphs of the relationship between Sa (Figure 3), Sz (Figure 4) and Sq (Figure 5) values and feed and cutting speed.
It was found that under dry and wet machining conditions the feed has the greatest influence on the Sa, Sz and Sq texture parameters. The direct effect of the cutting speed and the mutual influence of the feed and cutting speed have only a slight effect on parameters tested. Under MQL and MQL+EP machining conditions, Sa, Sz and Sq values are affected by a feed, cutting speed and their mutual interaction.
During dry and wet turning, lower Sa, Sz and Sq values were registered in conditions of lower feeds and cutting speeds. When turning under MQL and MQL+EP conditions, lower Sa, Sz and Sq values depended on the mutual interaction of the feed and cutting speed.

3.3. The Efficiency of Cooling Methods

Figure 6 shows the areas of minimum (0.4–0.8 μm), middle (0.8–1.3 μm) and maximum (1.3–15.0 μm) Sa values obtained under dry, wet, MQL and MQL+EP conditions.
When dry machining, minimum Sa was registered for lower f and medium and higher vc values, middle Sa—for medium f and medium and higher vc values, maximum Sa—for higher f and lower vc values. Under wet machining conditions, minimum Sa was obtained for lower f and medium and higher vc, middle values—for medium and higher f with all vc, maximum Sa—for higher f and vc. Under MQL conditions, minimum Sa values were registered for lower f, medium and higher cutting speeds, middle values—for medium and higher feeds in the investigated cutting speed range, maximum values—for medium feeds and cutting speeds and also for lower feeds and higher cutting speeds. Under MQL+EP conditions, minimum surface roughness values were obtained for lower feeds and medium cutting speeds, as well as for medium feeds and cutting speeds, middle values—for medium feeds and higher cutting speeds, maximum values—for medium feeds and cutting speeds, as well as for higher feeds and lower cutting speeds.
Bagaber and Yusoff [33] concluded that dry machining is optimal for clean production. To reduce high cutting temperatures, machining fluids are usually used. They have a negative impact on human health and the environment. Therefore, percentage changes in the roughness parameters Sa, Sz and Sq obtained under wet machining and under dry machining conditions were compared.
The main dividing line (black dotted line) of the Sa value changes was registered with f~0.2 mm/rev (Figure 7). During wet machining compared to dry machining the Sa parameter decreased by ~8–26% or increased by ~20–100%. For MQL machining in comparison with dry machining, the Sa parameter was reduced by ~18–43% or increased by ~22–541%. Cutting under MQL+EP conditions in comparison with dry cutting reduced the Sa value by ~3–48% or increased it by ~38–690%.
In the case of changes in the Sz value, no similar dividing line was registered for the range of machining parameters used (Figure 8). During wet turning in comparison with dry machining, the Sz parameter decreased by ~12–40% and increased by ~5–132%. For MQL machining in comparison with dry turning the Sz parameter decreased by ~39–48% or increased by ~6–271%. When machining under MQL+EP conditions, the Sz parameter decreased by ~1–38% compared to dry turning or increased by ~14–500%.
The main dividing line (black dotted line) of the Sq value changes was registered with f~0.2 mm/rev (Figure 9). During wet machining compared to dry machining the Sq parameter decreased by ~5–21% or increased by ~23–100%. For MQL turning in contrast to dry turning, the Sq parameter was reduced by ~20–40% or increased by ~26–523%. Cutting under MQL+EP conditions in comparison with dry cutting reduced the Sq value by ~2–43% or increased it by ~43–661%.
For the stainless steel tested, in particular in test points 5–7 of the Table 1, significant percentage discrepancies were obtained for the parameters Sa, Sz and Sq depending on the processing conditions. These changes may be result from poor machinability of stainless steels and may be associated, among others, with a strong tendency to deformation reinforcement or build-up-edge formation [34].

3.4. The Topography of Surfaces Tested

It is known that surface and subsurface properties depend in particular on surface topography. Kaynak et al. [35] have noted that a more favourable surface topography can ensure a longer use of the product.
Figure 10 shows three-dimensional images and contour maps of the surface after turning with vc~280 m/min and f~0.094 mm/rev under different cutting conditions. After MQL machining, irregularly distributed peaks, some of them of significant height, were observed on the surface. In the case of other cooling methods, unfavourable feed traces in the form of irregular peaks and pits were observed on the surface. The changes observed on the surface are the result of plastic deformation of the material.
Figure 11 shows three-dimensional images and contour maps of the surface after turning with vc~456 m/min and f~0.27 mm/rev. Feed traces were observed on the surface, that are typical of turning. After dry machining, the surface had irregular pits, narrow and high peaks. After wet machining, irregular pits and wide peaks were observed on the surface. After MQL machining, narrow and high ridges with irregular peaks and irregular and deep pits were found on the surface. After processing with MQL+EP, irregular pits and ridges were visible on the surface.
Figure 12 shows three-dimensional images and contour maps of the surface after turning with vc~195 m/min and f~0.36 mm/rev. Feed traces were observed on the surface, that are typical of turning. After dry processing, narrow and thin ridges and wide pits were formed on the surface. After wet processing, ridges and irregular pits were visible on the surface. After near-dry processing, very high ridges and very deep pits were observed on the surface.
Typical texture irregularities on the surface of the machine, namely peaks on 3D images and pits on contour maps, are marked in Figure 10, Figure 11 and Figure 12 with black dotted lines.
It can be concluded on the basis of surface topography analysed that an increase in feed causes an increase in the height of ridges on the surface of 17-4 PH stainless steel regardless of the cooling conditions.

3.5. Material Ratio Curves

Based on the shape of the material ratio curve, it was possible to evaluate the tribological behaviour of the surface under analysis. The so-called progressive material ratio curve indicates that the surface analysed has rounded peaks of roughness profiles and will be more resistant to wear in comparison with a digressive shape of these curves with sharp peaks.
Figure 13 shows the material ratio curves and distributions of height of micro-peaks on the surface after finish machining with cooling conditions used for the minimum Sa values (vc~280 m/min and f~0.094 mm/rev), medium Sa values (vc~456 m/min and f~0.27 mm/rev) and maximum Sa values (vc~194 m/min and f~0.36 mm/rev).
For minimum Sa (0.4–0.8 μm) under dry, wet and MQL+EP conditions, an anisotropic mixed character of the surface peaks was observed. Whereas, for MQL conditions an anisotropic mixed character with a very large participation of random component was seen.
For medium Sa (0.8–1.3 μm) under dry, wet and MQL+EP cooling conditions, an anisotropic cyclical character of the surface peaks was observed, and for MQL machining an anisotropic mixed character with a high participation of random component was registered.
For maximum Sa (1.3–15.0 μm), an anisotropic cyclical determined character of the surface peaks was registered for all conditions tested.
The obtained characteristics of the material ratio curves and distributions of peak heights of stainless steel tested are typical for finishing turning, as Oczoś and Liubimov described [36].

3.6. Surface Texture Isotropy

The isotropy of the surface topography indicates the stability of its structure in all directions. In other words, it is a generally symmetrical surface texture according to all possible axes of symmetry.
Figure 14 presents surface structure features after finish cutting under the analysed cooling conditions for minimum roughness (vc~280 m/min and f~0.094 mm/rev), medium roughness (vc~456 m/min and f~0.27 mm/rev) and maximum roughness (vc~194 m/min and f~0.36 mm/rev).
In the range of Sa = 0.4–0.8 μm, the surface isotropy of ~20% was registered after dry and wet cutting. When machining under MQL conditions, the isotropy of the surface was the highest (~60%), whereas under MQL+EP conditions it was the lowest (~3%). In the range of Sa = 0.8–1.3 μm and Sa = 1.3–15.0 μm, a small, similar surface isotropy ~6–8% and ~9–10%, respectively, was observed under all cooling conditions investigated. Therefore, it can be stated that the feed and cooling conditions influence the isotropic properties of the surface, as confirmed by Krolczyk et al. [20].

4. Conclusions

This paper presents an analysis of changes in the 17-4PH steel chip shapes and surface topography parameters under different machining conditions in a wide feed and cutting speed ranges. Selected amplitude parameters of the surface topography, curves of material ratio and distribution of roughness micro-peaks as well as the efficiency of cooling methods used were investigated. The analysis of the research results revealed that:
  • Under dry, wet, MQL and MQL+EP conditions, the favourable short spiral chips were registered for vc~456 m/min and f~0.27 mm/rev.
  • When dry and wet turning, lower Sa, Sz and Sq surface texture parameters occur in lower feeds and in the wide cutting speed range, while for MQL and MQL+EP conditions the location of the area of minimum values of Sa, Sz and Sq depends both on the feed and cutting speed, as well as on their mutual interaction.
  • The application of the PSI method allowed an effective analysis of the influence of a wide range of factors studied on the surface texture parameters, including both direct and mutual effects.
  • Compared to dry machining, the Sa surface texture parameter for wet machining was reduced by ~26%, MQL by ~43% and MQL+EP by ~48%; Sz parameter for wet machining by ~40%, MQL by ~48% and MQL+EP by ~38% and Sq parameter for wet machining by ~21%, MQL by ~40% and MQL+EP by ~43%.
  • In the case of minimum Sa values under dry, wet and MQL+EP cutting irregular small feed traces in the form of pits and peaks are observed, but under the MQL conditions irregularly distributed peaks are formed on the surface, some of them of a significant height. In the case of medium and maximum Sa values, traces in the form of deep pits and high peaks typical for turning feed effect were observed under all cooling conditions.
  • Under all cooling conditions tested in the range Sa = 0.4–0.8 μm the surface texture has a mixed anisotropic character. An anisotropic periodic character and an anisotropic mixed character of the surface texture are observed under dry, wet and MQL+EP conditions in the range Sa= 0.8–1.3 μm and under MQL conditions, respectively. In the range Sa = 1.3–15.0 μm under all the examined conditions an anisotropic periodically determined character of the surface tested is registered.
  • In the range Sa = 0.4–0.8 μm under dry and wet cutting, the ~20% surface isotropy, under MQL conditions ~60%, and under MQL+EP conditions of ~3% were registered. In the range Sa = 0.8–15.0 μm, the surface isotropy in the range from ~6% to ~10% was found under all cooling conditions studied.

Author Contributions

The individual contributions of the authors: conceptualization—E.F.; methodology—E.F., K.L.; software—K.L.; formal analysis—K.L., G.M.K.; investigation K.L., E.F.; data curation—K.L.; writing—original draft preparation—K.L., E.F., G.M.K.; writing—review and editing—G.M.K., S.L.; visualization—K.L.; supervision—G.M.K., S.L.; project administration—S.L. All authors have read and agreed to the published version of the manuscript.

Funding

The authors gratefully acknowledge the financial support from the program of the Polish Minister of Science and Higher Education under the name “Regional Initiative of Excellence” in 2019–2022, project no. 003/RID/2018/19, funding amount 11 936 596.10 PLN”.

Acknowledgments

The authors would like to thank Mariusz Władowski from OPTOTOM for sharing the Sensofar S Neox optical profilometer and the support in the measurements.

Conflicts of Interest

The authors declare no conflict of interest.

References

  1. Ahlhelm, M.; Günther, P.; Scheithauer, U.; Schwarzer, E.; Günther, A.; Slawik, T.; Moritz, T.; Michaelis, A. Innovative and novel manufacturing methods of ceramics and metal ceramic composites for biomedical applications. J. Eur. Ceram. Soc. 2016, 36, 2883–2888. [Google Scholar] [CrossRef]
  2. Mutlu, I.; Oktay, E. Characterization of 17-4 PH stainless steel foam for biomedical applications in simulated body fluid and artificial saliva environments. Mat. Sci. Eng. C 2013, 33, 1125–1131. [Google Scholar] [CrossRef] [PubMed]
  3. Karthik, D.; Kalainathan, S.; Swaroop, S. Surface modification of 17-4 PH stainless steel by laser peening without protective coating process. Surf. Coat. Tech. 2015, 278, 138–145. [Google Scholar] [CrossRef]
  4. Asri, R.I.M.; Harun, W.S.W.; Samykano, M.; Lah, N.A.C.; Ghani, S.A.C.; Tarlochan, F.; Raza, M.R. Corrosion and surface modification on biocompatible metals: A review. Mater. Sci. Eng. C 2017, 77, 1261–1274. [Google Scholar] [CrossRef] [Green Version]
  5. Karam, S.; Teti, R. Wavelet transform feature extraction for chip form recognition during carbon steel turning. Procedia CIRP 2013, 12, 97–102. [Google Scholar] [CrossRef]
  6. Leksycki, K.; Feldshtein, E. On the analysis chip shaping after finishing turning of Ti6Al4V titanium alloy under drt, wet and MQL conditions. Arch. Mech. Technol. Mater. 2019, 39, 36–40. [Google Scholar] [CrossRef] [Green Version]
  7. Dosbaeva, J.; Fox-Rabinovich, G.; Dasch, J.; Veldhuis, S. Enhancement of Wet- and MQL-Based Machining of Automotive Alloys Using Cutting Tools with DLC/Polymer Surface Treatments. J. Mater. Eng. Perform. 2008, 17, 346–351. [Google Scholar] [CrossRef]
  8. Tasdelen, B.; Thordenberg, H.; Olofsson, D. An experimental investigation on contact length during minimum quantity lubrication (MQL) machining. J. Mater. Process. Technol. 2008, 203, 221–231. [Google Scholar] [CrossRef]
  9. Liu, C.; He, Y.; Wang, Y.; Li, Y.; Wang, S.; Wang, L.; Wang, Y. An investigation of surface topography and workpiece temperature in whirling milling machining. Int. J. Mech. Sci. 2019, 164, 105182. [Google Scholar] [CrossRef]
  10. Ying, X.; Yang, Q.; Pei, Q.G.; Yang, L. The Surface Topography in Machining of Medical Metallic Materials: A Review. Mater. Sci. Forum 2016, 681, 127–132. [Google Scholar]
  11. Rahman, S.S.; Ashraf, M.Z.I.; Amin, A.K.M.N.; Bashar, M.S.; Ashik, M.F.K.; Kamruzzaman, M. Tuning nanofluids for improved lubrication performance in turning biomedical grade titanium alloy. J. Clean. Prod. 2019, 206, 180–196. [Google Scholar] [CrossRef]
  12. Krolczyk, G.M.; Nieslony, P.; Maruda, R.W.; Wojciechowski, S. Dry cutting effect in turning of duplex stinless steel as a key factor in clean production. J. Clean. Prod. 2017, 142, 3343–3354. [Google Scholar] [CrossRef]
  13. Krolczyk, G.M.; Maruda, R.W.; Krolczyk, J.B.; Wojciechowski, S.; Mia, M.; Nieslony, P.; Budzik, G. Ecological trends in machining as a key factor in sustainable production–A review. J. Clean. Prod. 2019, 218, 601–615. [Google Scholar] [CrossRef]
  14. Pereira, O.; Rodriguez, A.; Fernandez-Abia, A.I.; Barreiro, J.; Lopez de Lacalle, L.N. Cryogenic and minimum quantity lubrication for an eco-efficiency turning of AISI 304. J. Clean. Prod. 2016, 139, 440–449. [Google Scholar] [CrossRef]
  15. Zou, B.; Zhou, H.; Huang, C.; Xu, K.; Wang, J. Tool damage and machined-surface quality using hot-pressed sintering Ti(C7N3)/WC/TaC cermet cutting inserts for high-speed turning stainless steels. Int. J. Adv. Manuf. Tech. 2015, 79, 197–210. [Google Scholar] [CrossRef]
  16. Sivaiah, P.; Chakradhar, D. Comparative evaluations of machining performance during turning of 17-4 PH stainless steel under cryogenic and wet machining conditions. Mach. Sci. Technol. 2018, 22, 147–162. [Google Scholar] [CrossRef]
  17. Sivaiah, P.; Chakradhar, D. Effect of cryogenic coolant on turning performance characteristics during machining of 17-4 PH stainless steel: A comparison with MQL, wet, dry machining. JMST CIRP 2018, 21, 86–96. [Google Scholar] [CrossRef]
  18. Leksycki, K.; Feldshtein, E. The Geometric Surface Structure of X5CrNiCuNb16-4 Stainless Steel in Wet and Dry Finish Turning Conditions. In Advances in Manufacturing II; Diering, M., Wieczorowski, M., Brown, C., Eds.; Lecture Notes in Mechanical Engineering; Springer: Cham, Switzerland, 2019; Volume 5, pp. 183–194. [Google Scholar]
  19. Jerold, B.D.; Kumar, M.P. Machining of AISI 316 Stainless Steel under Carbon-Di-Oxide Cooling. Mater. Manuf. Process. 2012, 27, 1059–1065. [Google Scholar] [CrossRef]
  20. Krolczyk, G.M.; Maruda, R.W.; Krolczyk, J.B.; Nieslony, P.; Wojciechowski, S.; Legutko, S. Parametric and nonparametric description of the surface topography in the dry and MQCL cutting conditions. Measurement 2018, 121, 225–239. [Google Scholar] [CrossRef]
  21. Maruda, R.W.; Legutko, S.; Królczyk, G.M.; Raos, P. Influence of cooling conditions on the machining process under MQCL and MQL conditions. Tech. Gaz. 2015, 22, 965–970. [Google Scholar] [CrossRef] [Green Version]
  22. Rajaguru, J.; Arunachalam, N. A comprehensive investigation on the effect of flood and MQL coolant on the machinability and stress corrosion cracking of super duplex stainless steel. J. Mater. Process. Tech. 2020, 276, 116417. [Google Scholar]
  23. Elmunafi, M.H.S.; Kurniawan, D.; Noordin, M.Y. Use of Castor Oil as Cutting Fluid in Machining of Hardened Stainless Steel with Minimum Quantity of Lubricant. Procedia CIRP 2015, 26, 408–411. [Google Scholar] [CrossRef] [Green Version]
  24. Liu, G.; Huang, C.; Zou, B.; Wang, X.; Liu, Z. Surface integrity and fatigue performance of 17-4PH stainless steel after cutting operations. Surf. Coat. Tech. 2016, 307, 182–189. [Google Scholar] [CrossRef]
  25. Kochmański, P.; Nowacki, J. Activated gas nitriding of 17-4 PH stainless steel. Surf. Coat. Tech. 2006, 200, 6558–6562. [Google Scholar] [CrossRef]
  26. Liu, G.; Zou, B.; Huang, C.; Wang, X.; Wang, J.; Liu, Z. Tool damage and its effect on the machined surface roughness in high speed face milling the 17-4PH stainless steel. Int. J. Adv. Manuf. Tech. 2016, 83, 257–264. [Google Scholar] [CrossRef]
  27. Vengudusamy, B.; Grafl, A.; Novotny-Farkas, F.; Schimmel, T.; Adam, K. Tribological behaviour of antiwear additives used in hydraulic applications: Synergistic or antagonistic with other surface-active additives? Tribol. Int. 2013, 167, 199–210. [Google Scholar] [CrossRef]
  28. Maruda, R.W.; Krolczyk, G.M.; Niesłony, P.; Krolczyk, J.B.; Legutko, S. Chip formation zone analysis during the turning of austenitic stainless steel 316L under MQCL cooling condition. Procedia Eng. 2016, 149, 297–304. [Google Scholar] [CrossRef] [Green Version]
  29. Maruda, R.W.; Krolczyk, G.M.; Feldshtein, E.; Pusavec, F.; Szydlowski, M.; Legutko, S.; Sobczak-Kupiec, A. A study on droplets sizes, their distribution and heat exchange for minimum quantity cooling lubrication (MQCL). Int. J. Mach. Tools Manuf. 2016, 100, 81–92. [Google Scholar] [CrossRef]
  30. Wang, Y.; Zou, B.; Wang, J.; Wu, Y.; Huang, C. Effect of the progressive tool wear on surface topography and chip formation in micro-milling of Ti–6Al–4V using Ti(C7N3)-based cermet micro-mill. Tribol. Int. 2020, 141, 105900. [Google Scholar] [CrossRef]
  31. Statnikov, R.B.; Statnikov, A.R. The Parameter Space Investigation Method Toolkit; Artech House: Boston, MA, USA, 2011. [Google Scholar]
  32. Michailidis, N. Variations in the cutting performance of PVD-coated tools in milling Ti6Al4V, explained through temperature-dependent coating properties. Surf. Coat. Tech. 2016, 304, 325–329. [Google Scholar] [CrossRef]
  33. Bagaber, S.A.; Yusoff, A.R. Multi-objective optimization of cutting parameters to minimize power consumption in dry turning of stainless steel 316. J. Clean. Prod. 2017, 157, 30–46. [Google Scholar] [CrossRef] [Green Version]
  34. Grzesik, W. Advanced Machining Processes of Metallic Materials: Theory, Modelling and Applications, 2nd ed.; Elsevier: Amsterdam, The Netherlands, 2017. [Google Scholar]
  35. Kaynak, Y.; Lu, T.; Jawahir, I.S. Cryogenic Machining-induced Surface Integrity: A Review and Comparison with Dry, MQL, and Flood-cooled Machining. Mach. Sci. Technol. 2014, 18, 149–198. [Google Scholar] [CrossRef]
  36. Oczoś, K.E.; Liubimov, V. Struktura Geometryczna Powierzchni. Podstawy Klasyfikacji z Atlasem Charakterystycznych Powierzchni Kształtowych; Oficyna wydawnicza Politechniki Rzeszowskiej: Rzeszów, Poland, 2003. (In Polish) [Google Scholar]
Materials 13 02188 g001 550
Figure 1. Location of research points on the X1 and X2 axes.
Figure 1. Location of research points on the X1 and X2 axes.
Materials 13 02188 g001
Materials 13 02188 g002 550
Figure 2. Chip shapes after finish turning of the steel tested.
Figure 2. Chip shapes after finish turning of the steel tested.
Materials 13 02188 g002
Materials 13 02188 g003 550
Figure 3. Sa dependence on cutting parameters under: (a) dry; (b) wet; (c) MQL; (d) MQL+EP conditions.
Figure 3. Sa dependence on cutting parameters under: (a) dry; (b) wet; (c) MQL; (d) MQL+EP conditions.
Materials 13 02188 g003
Materials 13 02188 g004 550
Figure 4. Sz dependence on cutting parameters under: (a) dry; (b) wet; (c) MQL; (d) MQL+EP conditions.
Figure 4. Sz dependence on cutting parameters under: (a) dry; (b) wet; (c) MQL; (d) MQL+EP conditions.
Materials 13 02188 g004
Materials 13 02188 g005 550
Figure 5. Sq dependence on cutting parameters under: (a) dry; (b) wet; (c) MQL; (d) MQL+EP conditions.
Figure 5. Sq dependence on cutting parameters under: (a) dry; (b) wet; (c) MQL; (d) MQL+EP conditions.
Materials 13 02188 g005
Materials 13 02188 g006 550
Figure 6. Areas of minimum, medium and maximum Sa values of the surface under: (a) dry; (b) wet; (c) MQL; (d) MQL+EP conditions.
Figure 6. Areas of minimum, medium and maximum Sa values of the surface under: (a) dry; (b) wet; (c) MQL; (d) MQL+EP conditions.
Materials 13 02188 g006
Materials 13 02188 g007 550
Figure 7. Average percentage changes in the Sa roughness parameter under: (a) wet turning; (b) MQL; (c) MQL+EP conditions in comparison with dry turning.
Figure 7. Average percentage changes in the Sa roughness parameter under: (a) wet turning; (b) MQL; (c) MQL+EP conditions in comparison with dry turning.
Materials 13 02188 g007
Materials 13 02188 g008 550
Figure 8. Average percentage changes in the Sz roughness parameter under: (a) wet turning; (b) MQL; (c) MQL+EP conditions in comparison with dry turning.
Figure 8. Average percentage changes in the Sz roughness parameter under: (a) wet turning; (b) MQL; (c) MQL+EP conditions in comparison with dry turning.
Materials 13 02188 g008
Materials 13 02188 g009 550
Figure 9. Average percentage changes in the Sq roughness parameter under: (a) wet turning; (b) MQL; (c) MQL+EP conditions in comparison with dry turning.
Figure 9. Average percentage changes in the Sq roughness parameter under: (a) wet turning; (b) MQL; (c) MQL+EP conditions in comparison with dry turning.
Materials 13 02188 g009
Materials 13 02188 g010 550
Figure 10. Three-dimensional images and contour maps of the surface machined with a speed of vc~280 m/min and feed of f~0.094 mm/rev obtained under processing conditions: (a) dry; (b) wet; (c) MQL; (d) MQL+EP.
Figure 10. Three-dimensional images and contour maps of the surface machined with a speed of vc~280 m/min and feed of f~0.094 mm/rev obtained under processing conditions: (a) dry; (b) wet; (c) MQL; (d) MQL+EP.
Materials 13 02188 g010
Materials 13 02188 g011 550
Figure 11. Three-dimensional images and contour maps of the surface machined with a speed of vc~456 m/min and feed of f~0.27 mm/rev obtained under processing conditions: (a) dry; (b) wet; (c) MQL; (d) MQL+EP.
Figure 11. Three-dimensional images and contour maps of the surface machined with a speed of vc~456 m/min and feed of f~0.27 mm/rev obtained under processing conditions: (a) dry; (b) wet; (c) MQL; (d) MQL+EP.
Materials 13 02188 g011
Materials 13 02188 g012 550
Figure 12. Three-dimensional images and contour maps of the surface machined with a speed of vc~195 m/min and feed of f~0.36 mm/rev obtained under processing conditions: (a) dry; (b) wet; (c) MQL; (d) MQL+EP.
Figure 12. Three-dimensional images and contour maps of the surface machined with a speed of vc~195 m/min and feed of f~0.36 mm/rev obtained under processing conditions: (a) dry; (b) wet; (c) MQL; (d) MQL+EP.
Materials 13 02188 g012
Materials 13 02188 g013 550
Figure 13. Material ratio curves and distributions of peak heights after finish turning of the steel tested.
Figure 13. Material ratio curves and distributions of peak heights after finish turning of the steel tested.
Materials 13 02188 g013
Materials 13 02188 g014 550
Figure 14. Surface structure direction after finish turning of the steel tested.
Figure 14. Surface structure direction after finish turning of the steel tested.
Materials 13 02188 g014
Table
Table 1. Point coordinates.
Table 1. Point coordinates.
VariablesTest Points Coordinates
1234567
X10.50000.25000.75000.87500.37500.62500.1250
X20.50000.75000.25000.62500.12500.37500.8750
Table
Table 2. Statistical models for Sa, Sz and Sq calculations after finish processing steel tested under different cooling conditions.
Table 2. Statistical models for Sa, Sz and Sq calculations after finish processing steel tested under different cooling conditions.
Dry Cutting
Sa = −0.6872 − 4.4729f + 0.0076Vc + 27.1238f2 − 0.0003fVc − 1.0873·10−5Vc2
Sz = 8.0803 − 26.2563f + 0.014Vc + 129.25f2 + 0.0035fVc − 2.312(E − 5)Vc2
Sq = 0.0457 − 5.3189f + 0.0039Vc + 31.3739f2 + 0.0003fVc − 5.7246(E − 6)Vc2
Wet Cutting
Sa = −1.7266 − 3.9803f + 0.0131Vc + 32.076f2 − 0.0136fVc − 1.2922E − 5Vc2
Sz= −26.0225 − 70.2708f + 0.229Vc + 213.7683f2 + 0.0489fVc − 0.0003Vc2
Sq = −0.8632 − 2.0673f + 0.0079Vc + 30.6233f2 − 0.0168fVc − 4.7939(E − 6)Vc2
MQL Cutting
Sa = 21.3533 − 7.3691f − 0.1275Vc + 233.9231f2 − 0.2742fVc + 0.0003Vc2
Sz = 85.7288 − 602.4137f − 0.0937Vc + 1726.6324f 2 − 0.4679fVc + 0.0003Vc2
Sq = 8.0883 − 38.527f − 0.0372Vc + 318.9039f2 − 0.2655fVc + 0.0001Vc2
MQL+EP Cutting
Sa = 17.8488 + 25.895f − 0.1264Vc + 163.9226f2 − 0.298fVc + 0.0003Vc2
Sz = 26.4998 + 294.6575f − 0.2883Vc + 403.2388f2 − 1.4351fVc + 0.0009Vc2
Sq = 21.3113 + 30.0252f − 0.1502Vc + 195.6086f2 − 0.3528fVc + 0.0003Vc2

Share and Cite

MDPI and ACS Style

Leksycki, K.; Feldshtein, E.; Królczyk, G.M.; Legutko, S. On the Chip Shaping and Surface Topography When Finish Cutting 17-4 PH Precipitation-Hardening Stainless Steel under Near-Dry Cutting Conditions. Materials 2020, 13, 2188. https://doi.org/10.3390/ma13092188

AMA Style

Leksycki K, Feldshtein E, Królczyk GM, Legutko S. On the Chip Shaping and Surface Topography When Finish Cutting 17-4 PH Precipitation-Hardening Stainless Steel under Near-Dry Cutting Conditions. Materials. 2020; 13(9):2188. https://doi.org/10.3390/ma13092188

Chicago/Turabian Style

Leksycki, Kamil, Eugene Feldshtein, Grzegorz M. Królczyk, and Stanisław Legutko. 2020. "On the Chip Shaping and Surface Topography When Finish Cutting 17-4 PH Precipitation-Hardening Stainless Steel under Near-Dry Cutting Conditions" Materials 13, no. 9: 2188. https://doi.org/10.3390/ma13092188

APA Style

Leksycki, K., Feldshtein, E., Królczyk, G. M., & Legutko, S. (2020). On the Chip Shaping and Surface Topography When Finish Cutting 17-4 PH Precipitation-Hardening Stainless Steel under Near-Dry Cutting Conditions. Materials, 13(9), 2188. https://doi.org/10.3390/ma13092188

Note that from the first issue of 2016, this journal uses article numbers instead of page numbers. See further details here.

Article Metrics

Back to TopTop