Evaluation of the Performance of a Pcbn Tool in Turning Aisi D2 Hardened Steel in Continuous and Interrupted Cutting

Evaluation of the Performance of a Pcbn Tool in Turning Aisi D2 Hardened Steel in Continuous and Interrupted Cutting | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Evaluation of the Performance of a Pcbn Tool in Turning Aisi D2 Hardened Steel in Continuous and Interrupted Cutting Ernane Felipe Dias, Caio Cesar Gonçalves Coutinho Barroso, Sandro Cardoso Santos This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-4059612/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 24 Sep, 2024 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted 5 You are reading this latest preprint version Abstract Important technological advances in the mechanical manufacturing industry have increasingly generated good results with the turning of hardened materials, using polycrystalline cubic boron nitride (PCBN) tools, mainly replacing abrasive processes. Tool steels play varied and essential roles in various industrial applications, such as dies and punches for forming and cutting. This work involves the evaluation the performance of a PCBN tool in turning quenched and tempered AISI D2 steel, both in continuous cutting and interrupted cutting conditions, in the finishing operation with dry machining. The surface roughness was evaluated in the parameters (R a , R t and R z ), the wear suffered by the tools, their mechanisms and morphological analysis of the chips. Tests were carried out with different cutting speeds (60, 130, 200 and 240 m/min), maintaining a constant feed rate of 0.15 mm/rev and a cutting depth of 0.2 mm. The results indicated that the most evident wear was crater and flank in the continuous cut, while in the interrupted cut there was the presence of chipping and catastrophic failure. Wear mechanisms, such as adhesion (attrition), abrasion and diffusion were prominently observed. Furthermore, the tests showed that the increase in flank wear did not necessarily result in an increase in surface roughness, and that the wear mechanism changed with the increase in cutting speed. In the continuous cutting condition, the tool achieved more satisfactory performance, especially at higher cutting speeds (130, 200 and 240 m/min). In interrupted cutting, there is a predominance of catastrophic failure mainly in the ranges of 60 and 130 m/min and better performance at 200 m/min within the ranges evaluated. Hard Turning. PCBN Tool. Tool Wear. AISI D2 steel. Roughness Figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 1. Introduction The turning of hardened steels has been widely applied in the industry due to its favorable outcomes compared to other processes, such as grinding, particularly in the automotive and molds and dies industries. Furthermore, it allows manufacturers to execute their processes in a simplified manner and achieve good results in terms of quality and surface integrity [ 1 ]. To ensure this, the equipment must possess characteristics that guarantee satisfactory machining, such as dynamic stability to prevent disturbances that may affect the operation, leading, for instance, to excessive vibration, play in the stroke, and sufficient power to meet the required cutting parameters [ 2 ]. The processes employed in finishing operations on hardened materials were traditionally carried out using abrasive methods such as grinding or electrical discharge machining (EDM) [ 3 ]. Due to technological advancements, which have enhanced the rigidity and dynamic stability of machine tools, coupled with improvements in the materials of cutting tools characterized by high hardness and resistance to wear at elevated temperatures, machining of these materials has become feasible through turning processes [ 4 ]. According to [ 5 ], hard turning can produce workpieces with surface finishes comparable to those achieved through grinding. A diverse range of tool materials, such as cemented carbide, ceramics, polycrystalline diamond (PCD), and cubic boron nitride (CBN), finds extensive use in the machining of hardened materials. The latter is identified as a global trend and considered the optimal choice [ 6 ]. This trend is attributed to its superior thermal conductivity and hardness when compared to other tool materials. In hard turning processes, small cutting depths are employed due to the hardness of the materials being machined. Typically, these cutting depth values are equal to or smaller than the radius of the insert tip [ 1 ]. Authors [ 7 ] compared a conventional insert with others with straightening edge geometry to observe the behavior of the output parameters when machining heat-treated AISI D2 steel with two hardness values (55 and 60 HRC). In the work of [ 8 ], the performance and wear mechanisms were analyzed in a PCBN cutting tool in the turning of dry-machined AISI D2 hardened steel. In addition to high hardness (40-60HRC), cutting parameters such as cutting speed of 250 m/min, feed of 0.1 mm/ rev and a constant cutting depth of 0.15 mm were applied. As a result, they observed that flank wear increases linearly with increasing hardness of AISI D2 steel. While turning of hardened steel demonstrates several advantages over the grinding process, it cannot be asserted that this method replaces all practical operations on grinders. This is because turning, grinding, and other abrasive finishing operations generate different surface structures that can influence their functional properties due to these distinct topographical characteristics [ 9 ]. The study of surface and subsurface characteristics of materials obtained through machining processes, such as microhardness, residual stress analysis, roughness, and phase transformation, becomes crucial in the pursuit and understanding of the phenomena involved in the process, as well as in reducing final component failures. The performance of these components is highly dependent on the characteristics and properties of the final surfaces achieved [ 10 ]. Tool wear can stem from two primary sources: thermal or mechanical factors. The wear mechanisms associated with tool wear are categorized into abrasion, oxidation, attrition, and diffusion. A comprehensive analysis of wear mechanisms is very important for interpreting behavior and understanding the dynamic interaction between the tool and the chip [ 11 ]. Surface roughness is the most commonly visible result of any machining processes that can be used to characterize process quality as it determines the functional properties of machined components. This occurs because surface roughness alters contact tribology, which is key to processes ranging from wear, adhesion to friction, lubrication, and coating systems [ 12 ]. This, in turn, influences the fatigue resistance, creep resistance, corrosion resistance and service life of the machined component. Therefore, adapting and controlling the roughness of the machined surface to a high level of precision is a fundamental requirement for many relevant applications [ 13 ]. In this study, the performance of a PCBN tool with 75% by volume of CBN bonded to a Titanium (Ti) matrix was investigated in turning AISI D2 hardened steel under continuous and interrupted cutting conditions. The objective of this work is to analyze the behavior of wear mechanisms and evaluate the influence of variation in cutting speed and its correlation with surface roughness. Furthermore, to study whether the percentage of CBN content, as well as the binding material, influenced the resistance to abrasion and impact when machining of hardened tool steels. 2. Experimental Procedure The machined material was prepared in the form of Ø150 x 60 mm billets, coming from the same bar. The first operation carried out was pre -machining to prepare these materials. The machine tool used was a conventional ROMI lathe, model T-240, for machining the central holes and external diameters. Then, with the aid of wire electro-erosion machining, transversal cuts were made, reducing them to thicknesses close to the final measurements of the test piece. This process does not interfere, through thermal mechanisms, in the mechanical properties of the samples, unlike other conventional machining processes in which shear stresses are introduced. After this process, the discs were machined again on both sides, to remove the altered surface layer (white layer) for heat treatments. These were carried out in a salt bath oven with a capacity of Ø770 x 1400 mm. The tempering process initially occurred by heating the samples to 1020 ºC for 30 minutes. Then cooling to a temperature of 500 ºC for the first tempering for about 3 hours. Two more tempers were also carried out, both at 500 ºC for a period of 3 hours. A sample of AISI D2 steel was characterized using optical emission spectrometry using the SPECTROMAXx spectrometer, to verify its chemical composition. To evaluate microstructural changes, samples were prepared, embedded in resin, and etched with Vilella for approximately 20 seconds. The evaluation was carried out with the aid of an OLYMPUS GX51 optical microscope. A hardness test on the Rockwell C scale was also carried out with the Dura Visio DV30 universal hardness tester before and after heat treatments. The machine used for turning is a CNC lathe with a nominal available power of 7.5 kW, maximum rotation of 3500 RPM. To fix the specimens in the machine, it was necessary to machine jaws to create a support stop to facilitate correct fitting and depth adjustment, given that the disc format is used in research in facing operations. The inserts used had the ISO DCGW 11T304S14N-OAB-PCBN geometry. The CBN raw material used was of the compact class of BZN 9000. It has a high volume in percentage of CBN, around 75% volume in the matrix based on Titanium (Ti). It has an average particle size of 4µm. The tool holder used was SDJCL 2020K 11, with position angle (93º), tool attack angle (− 3º), orthogonal exit angle (0º), inclination angle (0º), tool body angle in in relation to the machine (0º), and angle of the tool body in relation to the part (0º). The geometry of the test piece is disc-shaped, containing a through hole in its center, as shown in Fig. 1 . This geometry induces greater rigidity due to reduced cantilever lengths. For the interrupted cut, tears were made on the face. Once the specimens were prepared, external dry turning began in successive passes in the radial direction (facing) for both continuous and interrupted cutting. Five passes of 0.2 mm cutting depth (ap) were made, totaling 1 mm of material removed for each determined cutting speed range (60, 130, 200 and 240 m/min). In each track, a new tool was selected. The feed was kept the same for all experiments f = 0.15 mm/rev. The surface finish of the machined part was measured using a roughness meter, taking measurements at three different points and the parameters R a , R z and R t . In analyzing tool wear, a USB digital microscope was used to measure pass after pass. After the tests, to evaluate the final state of the inserts, the samples were evaluated using a scanning electron microscope (SEM). The samples were enlarged focusing on the region where the wear occurred, thus being able to verify the mechanisms suffered by the tools. In addition, energy dispersive spectroscopy (EDS) analyzes were carried out to chemically evaluate the final state of the tools in the region where the wear occurred. 3. Results and discussion 3.1. Analysis of Chemical, Metallographic and Hardness Composition The result of the chemical analysis, obtained by optical emission spectrometry, is presented in Table 1 . Table 1 Chemical composition (wt.%) Carbon (C) Manganese (Mn) Chrome (Cr) Molybdenum (Mo) Vanadium (V) 1.58 0.32 11.67 0.68 0.83 The values found are consistent with those established through normative regulation. Figure 2 shows the microstructure of AISI D2 steel in its normalized state, without undergoing heat treatment of quenching and tempering at 200x magnification and Vilella reactive. Note the presence of ferrite and carbides, characteristic of this type of steel, due to its chemical composition, where, through the alloying elements, they promote the presence of carbides in the microstructure. After carrying out the final treatments, the microstructure is obtained, which can be seen in Fig. 3 . It is possible to observe the predominant presence of martensite throughout the analyzed region, formed from tempering, in addition to a large proportion of carbides characteristic of this material. Regarding hardness analysis, an average value of 15 HRC is found in the normalized state, this value being typically found in this type of steel without heat treatment. In relation to the values found after quenching and tempering heat treatment, the average value found was 60 HRC, reaching the initially established objective. 3.2. Analysis of Wear on Cutting Tools and Mechanisms Next, the results of the maximum flank wear (VB bmáx ) and the analysis of the mechanisms in each cutting speed range in the two machined conditions are presented. In Fig. 4 , the evolution of VB bmáx is presented as a function of the machined length (l f ) for the cutting speed curves in continuous and interrupted cutting conditions. In the analysis for continuous cutting at a cutting speed of 60 m/min, values are observed only from l f = 200 mm, having VB bmax = 0.19 mm and reaching a maximum value of 0.23 mm at the end of the passes. Regarding the cutting speed curve of 130 m/min, it was only possible to measure from 150 mm of machined length, starting with VB bmax = 0.07 mm, with a maximum wear value of 0.15 mm in l f = 250mm. In the cutting speed range of 200 m/min, only at the machined length of 200 mm, the VB bmax was 0.09 mm and maintained this value until the last pass. The evolution of maximum flank wear for Vc = 240 m/min presented values from the first pass of 0.06 mm, until reaching the maximum value of VB bmax = 0.28 mm. In interrupted cutting, in the cutting speed range of 60 m/min, it was not possible to carry out any measurements due to a catastrophic failure in the first instant of cutting. At 130 m/min, wear is measured only in the first pass (l f = 50 mm), as the tool failed in the next machined length. It was not possible to measure wear on the machined length of 250 mm in any of the cutting speed ranges, due to previous breaks and catastrophic failures. Assessments using scanning electron microscopy (SEM) are described in the next figures. In Fig. 5 , the final state of the tool in continuous cutting at cutting speeds of 60 m/min (A) and 130 m/min (B) is shown. At Vc at 60 m/min (A), it is possible to notice a detachment of material from the tool's exit surface and significant flank wear. The relative movement between the part and the tool promoted the detachment of both the adhered material itself and small particles from the tool. This situation characterizes the attrition mechanism that occurs at low cutting speeds and lower temperatures. An energy dispersive X-ray spectroscopy (EDS) coupled to (SEM) was carried out at a cutting speed of 60 m/min, which is presented in Table 2 . The result of the analysis showed the presence of elements such as Iron (Fe), Chromium (Cr) and Molybdenum (Mo) match the chemical composition of the machined specimen, characterizing material adhered to the tool. When analyzing Vc at 130 m/min (B), the presence of crater and flank wear was observed. From this speed range onwards, there was a change in the wear mechanism. Abrasion contributed to both types of wear, and in addition, the diffusion mechanism is highlighted due to the evidence of a smooth surface inside the crater, characteristic of the diffusive process. The results closely resemble those observed in other studies [ 14 ], [ 15 ] e [ 2 ]. Table 2 -The Energy Dispersive Spectroscopy (EDS) continuous cutting V c = 60 m/min Regions C (%) O (%) Ti (%) Al (%) Si (%) Cr (%) V (%) W (%) Fe (%) N (%) Mo (%) Inclusion 1 18,92 17,93 19,76 19,95 7,64 1,45 18,29 Inclusion 2 17,12 5,51 0,16 0,21 0,43 10,70 0,67 63,67 0,81 In Fig. 7 , the final state of the tool is shown in continuous cutting at cutting speeds of 200 m/min (A) and 240 m/min (B). In the range of 200 m/min the tool behaved satisfactorily until the penultimate pass. In general, the wear that occurs does not come from just one mechanism, but rather from a combination of several of them. The large number of carbides present and the resistance to high temperatures in hardened AISI D2 steel caused, in most of the cutting speeds studied, intense wear resulting in a reduced lifetime. Diffusion and abrasion mechanisms probably occurred, as they caused a considerable crater on the exit surface and the chipping process occurred in the last pass. In the test with a cutting speed of 240 m/min (highest value range recommended by the manufacturer), the tool behaved satisfactorily, especially when working with a new edge and in the subsequent pass. As can be seen, crater wear caused by abrasion mechanisms followed by diffusion was once again predominant, in addition to flank wear. According to [ 16 ], [ 17 ], the high temperatures present in the cutting region tend to stimulate the two mechanisms. This is because the removal of fragments from the tool by abrasion favors the exchange of particles between tool and chip (diffusion). No cracks or chips were identified. In the analyzes carried out for interrupted cutting, initially the cutting speeds of 60m/min and 130m/min behaved unsatisfactorily. In the first moments of cutting, the tool failed. The severe tribological condition, followed by the greater number of inputs and outputs, caused the tool to fail, unable to withstand the impacts of interrupted cutting. The toughness and hardness of the tool were not able to withstand these efforts driven by low cutting speeds. Figure 8 shows the tools after the end of the tests. In tests with the tool at higher cutting speeds (Fig. 9 ), there was a slightly more satisfactory performance than previous results. At Vc = 200 m/min, the test was carried out until the machined length was 200 mm, culminating in the last pass with the insert breaking. In the indication of the highest cutting speed range indicated by the manufacturer in Vc = 240 m/min, the tool managed to reach only 150 mm of machined length, culminating in catastrophic failure. 3.3. Roughness Analysis To evaluate the surface finish, the evolution of surface roughness was analyzed, comparing it in some aspects, such as the influence of cutting speed as a function of machining lengths, in continuous and interrupted cutting conditions. Although it is known that advancement is the most influential parameter in surface finishing [ 18 ], other conditions affect surface quality and must be evaluated for a better understanding of the process [ 19 ]. Initially, when observing the influence of cutting speed on the roughness of AISI D2 steel in continuous cutting, in the last pass (Fig. 10 -A), a similar behavior was noted in the three parameters evaluated. There was initially a reduction in roughness values at a cutting speed of 130 m/min compared to speeds of 60 m/min, 200 m/min and 240 m/min. In the two largest Vc , there was little variation in the results, showing a stable range for the continuous cutting condition. When evaluating the average roughness (R a ) (Fig. 10 -B), a better result is indicated for the cutting speed range of 130 m/min, which reached a value of R a = 0.416 µm, a favorable condition for finishing operations and which can be used to characterize machining quality, as it determines the functional properties of a machined component [ 20 ]. In the analysis of the interrupted cutting condition presented in Fig. 11 (A), the cutting speed range of 60 m/min does not appear in the graphs, as it was not possible to measure the roughness due to the break that occurred at the beginning of the cut. It is noted that the cutting speed range that obtained the lowest roughness evaluated was 240 m/min, with a value of R a = 0.549 µm in the second pass, and the highest roughness measured occurred with a cutting speed of 200 m/min in the last pass, with a value of 1.013 µm. From the second pass onwards, there were no roughness values for the range of 130 m/min, as the tool suffered breakage, preventing the continuation of the test. Also, there were no values for the 240 m/min range, starting from the fourth pass for the same reason. It was observed that the increase in cutting speed did not significantly influence the surface roughness values for the tool with the new edge. Therefore, in this range (130 to 240 m/min) the increase in cutting speed has little effect on surface quality when it comes to new tools. In general, roughness is increased by the evolution of wear. Figure 11 (B) shows an evaluation of only the first pass of the three roughness parameters evaluated. There was no significant difference in the ranges of Vc = 130, 200 and 240 m/min. 4. Conclusion The greatest evidence of wear that occurred in the continuous cut was crater and flank. As well as chipping and catastrophic failure in interrupted cutting. The wear mechanisms highlighted were adhesion and pullout (attrition), abrasion and diffusion. With the increase in cutting speed, a change in the wear mechanism in continuous cutting was observed, going from attrition ( Vc = 60 m/min) to abrasion and diffusion ( Vc = 130, 200 and 240 m/min), converging with information available in literature. The increase in cutting speed resulted in the expected increase in tool wear. In continuous cutting, the tool presented a more satisfactory performance, reaching 250 mm in machined length at all selected cutting speeds. When comparing cutting conditions, the highest measured value of VB bmax was 0.61 mm in interrupted cutting at 200 m/min. In the same range and machined length, a value of 0.09 mm was recorded in continuous cutting, which represents an increase of 6.7 times. In the cutting speed range of 130 m/min in continuous cutting, an average roughness (R a ) of 0.416µm was measured. This highly favorable result can be equivalent to rectification operations, making it viable to replace this process in certain situations. The tests showed that flank wear does not necessarily result in an increase in roughness, and, as it settles over a certain cutting time, the surface quality improves. The tool did not perform satisfactorily at lower cutting speeds (60 m/min), both for continuous and interrupted cutting, suggesting better performance at higher values. In interrupted cutting, the higher cutting speeds resulted in longer tool life compared to the lower tested speeds of 60 m/min and 130 m/min. The BZN9000 class was not tough enough to withstand the impacts caused by interrupted cutting and is not suitable for this type of operation. On the other hand, for continuous cutting, the use of higher speeds has demonstrated positive results in terms of increased productivity. Declarations Competing interests The authors Ernane Felipe Dias, Caio César Gonçalves Coutinho Barroso, and Sandro Cardoso Santos declare that they have no conflicts of interest or financial conflicts to disclose. Availability of data and material The authors confirm that the data supporting the findings of this study are available within the article. Code availability Not applicable Ethical approval All authors have previously approved this paper and judged that there is no ethical infringement. Consent to participate and publication All authors would like to declare that they have approved their participation and consent about the publication in this journal. Author Contributions Ernane Felipe Dias was responsible for the conceptualization, experimental work and writing of the manuscript. Caio César Barroso were contributed to experimental work and Sandro Cardoso were responsible for the revision of the manuscript and contributed to the technical discussion of the results. Sandro Cardoso was responsible for the supervision of the work and the availability of resources. Acknowledgements This work was conducted with the support of the Federal Centre of Technological Education of Minas Gerais (CEFET-MG), SENAI Itaúna CETEF Marcelino Corradi, SENAI Contagem Euvaldo Lodi, MAPAL Dr. Kress KG do Brazil, LCF Indústria Mecânica Ltda. and Metaltemper Tratamentos Térmicos de Metais. References Yousefi, S., Zohoor, M. Effect of cutting parameters on the dimensional accuracy and surface finish in the hard turning of MDN250 steel with cubic boron nitride tool, for developing a knowledge base expert system. 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Cite Share Download PDF Status: Published Journal Publication published 24 Sep, 2024 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted Editorial decision: Major Revisions Needed 19 Jul, 2024 Reviewers agreed at journal 05 Apr, 2024 Reviewers invited by journal 13 Mar, 2024 Editor assigned by journal 12 Mar, 2024 First submitted to journal 09 Mar, 2024 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-4059612","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":279237730,"identity":"5ddd08bd-f7bf-4762-aedc-7c210c37424d","order_by":0,"name":"Ernane Felipe Dias","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAA90lEQVRIiWNgGAWjYPACOQY+ZiD1AYjZ2InTYszABtTCOAOkhZloLUCSmQfEJqSFX/rswc8FFQZybOy8Bx/b/NomD3Qh44ePObi1SPblJUvPOGNgzMbMl2yc23fbsI2ZgVly5jbcWgzO8BhI87b9SWxj5jGTzu25zQjUwsbMi0eL/Rke49+8/wzqgVrMf1v23LYnqMWAB2g4b4NBAhvQFmaGH7cTCWqROMNjZs1zzADoBb5kyd6G28ltzIzNeP3C38NjfJunxkCen//swQ8//ty2nd/efPDDRzxakAAwUhjbQAzGBqLUQ7Qw/CFW8SgYBaNgFIwkAACFsUHz6rNRkgAAAABJRU5ErkJggg==","orcid":"https://orcid.org/0009-0004-5101-5453","institution":"Centro Federal de Educacao Tecnologica de Minas Gerais","correspondingAuthor":true,"prefix":"","firstName":"Ernane","middleName":"Felipe","lastName":"Dias","suffix":""},{"id":279237731,"identity":"e13a379e-e369-4f6d-a472-877fb3d3aca7","order_by":1,"name":"Caio Cesar Gonçalves Coutinho Barroso","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Caio","middleName":"Cesar Gonçalves Coutinho","lastName":"Barroso","suffix":""},{"id":279237732,"identity":"81ee22c6-4ff2-4c11-af6c-c48bd5143fa0","order_by":2,"name":"Sandro Cardoso Santos","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Sandro","middleName":"Cardoso","lastName":"Santos","suffix":""}],"badges":[],"createdAt":"2024-03-09 20:14:58","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-4059612/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-4059612/v1","draftVersion":[],"editorialEvents":[{"content":"https://doi.org/10.1007/s00170-024-14511-w","type":"published","date":"2024-09-24T15:57:36+00:00"}],"editorialNote":"","failedWorkflow":false,"files":[{"id":52757576,"identity":"76be7831-1701-4c1b-9b82-ca3e9299df87","added_by":"auto","created_at":"2024-03-15 12:01:40","extension":"png","order_by":1,"title":"Figure 1","display":"","copyAsset":false,"role":"figure","size":2032268,"visible":true,"origin":"","legend":"\u003cp\u003eGeometry of the specimens: 1- interrupted cut and 2 - continuous cut\u003c/p\u003e","description":"","filename":"figure1.png","url":"https://assets-eu.researchsquare.com/files/rs-4059612/v1/a77a55dd64bbcc4a4cb0ec0f.png"},{"id":52757590,"identity":"f99c075e-e048-40ff-a09c-652df10d8193","added_by":"auto","created_at":"2024-03-15 12:01:40","extension":"png","order_by":2,"title":"Figure 2","display":"","copyAsset":false,"role":"figure","size":10890117,"visible":true,"origin":"","legend":"\u003cp\u003eMicrostructure of AISI D2 steel – standardized\u003c/p\u003e","description":"","filename":"figure2.png","url":"https://assets-eu.researchsquare.com/files/rs-4059612/v1/4ba28c3595ccc0094c77d026.png"},{"id":52757578,"identity":"eb2bab39-fec7-453a-a6ee-b8533fad0c59","added_by":"auto","created_at":"2024-03-15 12:01:40","extension":"png","order_by":3,"title":"Figure 3","display":"","copyAsset":false,"role":"figure","size":9569584,"visible":true,"origin":"","legend":"\u003cp\u003eMicrostructure of AISI D2 steel – quenched and tempered\u003c/p\u003e","description":"","filename":"figure3.png","url":"https://assets-eu.researchsquare.com/files/rs-4059612/v1/8b9c7ca4f5996ebcf75ec3a8.png"},{"id":52757579,"identity":"a63fe62a-77ad-46de-9eab-413f3cef771f","added_by":"auto","created_at":"2024-03-15 12:01:40","extension":"png","order_by":4,"title":"Figure 4","display":"","copyAsset":false,"role":"figure","size":415348,"visible":true,"origin":"","legend":"\u003cp\u003eEvolution of VB\u003csub\u003ebmax \u003c/sub\u003eas a function of the machined length (l\u003csub\u003ef \u003c/sub\u003e) (A) Continuous cutting and (B) Interrupted cutting\u003c/p\u003e","description":"","filename":"figure4.png","url":"https://assets-eu.researchsquare.com/files/rs-4059612/v1/5f8b6cf86e0773aeb51e654a.png"},{"id":52758083,"identity":"12653726-82eb-4ccc-841b-ad08193e5ec4","added_by":"auto","created_at":"2024-03-15 12:09:42","extension":"png","order_by":5,"title":"Figure 5","display":"","copyAsset":false,"role":"figure","size":5297773,"visible":true,"origin":"","legend":"\u003cp\u003eAnalysis (SEM) in continuous section – (A) \u003csub\u003eVc \u003c/sub\u003e= 60 m/min (B) \u003csub\u003eVc \u003c/sub\u003e= 130 m/min\u003c/p\u003e","description":"","filename":"figure5.png","url":"https://assets-eu.researchsquare.com/files/rs-4059612/v1/7b3daec458f00cead8cbbdad.png"},{"id":52757612,"identity":"94bf79b2-d44b-42b1-aee5-89cdeecce9c6","added_by":"auto","created_at":"2024-03-15 12:01:40","extension":"png","order_by":6,"title":"Figure 6","display":"","copyAsset":false,"role":"figure","size":6197221,"visible":true,"origin":"","legend":"\u003cp\u003eAnalysis (SEM) in continuous cutting – (A) \u003csub\u003eVc \u003c/sub\u003e= 200 m/min (B) \u003csub\u003eVc \u003c/sub\u003e= 240 m/min\u003c/p\u003e","description":"","filename":"figure6.png","url":"https://assets-eu.researchsquare.com/files/rs-4059612/v1/c5d9fcf4be9f0436737a2fd5.png"},{"id":52758084,"identity":"281e14b8-0495-4c92-a732-38f0219bdae3","added_by":"auto","created_at":"2024-03-15 12:09:43","extension":"png","order_by":7,"title":"Figure 7","display":"","copyAsset":false,"role":"figure","size":9565635,"visible":true,"origin":"","legend":"\u003cp\u003eFinal state of tools in interrupted cutting - (A) \u003csub\u003eVc \u003c/sub\u003e60 m/min and (B) \u003csub\u003eVc \u003c/sub\u003e130 m/min\u003c/p\u003e","description":"","filename":"figure7.png","url":"https://assets-eu.researchsquare.com/files/rs-4059612/v1/baa41189942b79e457e04c51.png"},{"id":52757604,"identity":"a2d8f591-8c5b-4333-b53f-408a5e6eebe5","added_by":"auto","created_at":"2024-03-15 12:01:40","extension":"png","order_by":8,"title":"Figure 8","display":"","copyAsset":false,"role":"figure","size":6695277,"visible":true,"origin":"","legend":"\u003cp\u003eFinal state of tools in interrupted cutting (A) \u003csub\u003eVc \u003c/sub\u003e= 200 m/min (B) \u003csub\u003eVc \u003c/sub\u003e= 240 m/min\u003c/p\u003e","description":"","filename":"figure8.png","url":"https://assets-eu.researchsquare.com/files/rs-4059612/v1/b8ec60a3066d0fe2d8bfc71a.png"},{"id":52757610,"identity":"96552240-f22f-4bc5-a44c-b2192f51e5a5","added_by":"auto","created_at":"2024-03-15 12:01:40","extension":"png","order_by":9,"title":"Figure 9","display":"","copyAsset":false,"role":"figure","size":463133,"visible":true,"origin":"","legend":"\u003cp\u003e(A) Effect of cutting speed on the surface roughness of AISI D2 steel in the parameters R\u003csub\u003ea \u003c/sub\u003e, R\u003csub\u003ez \u003c/sub\u003eand R\u003csub\u003et \u003c/sub\u003e(B) average roughness (R\u003csub\u003ea \u003c/sub\u003e) as a function of varying cutting speeds – continuous cutting\u003c/p\u003e","description":"","filename":"figure9.png","url":"https://assets-eu.researchsquare.com/files/rs-4059612/v1/07da11c02cb54d9c5810bef6.png"},{"id":52757577,"identity":"6076fa34-ca7f-41f6-aaa2-9f31b8f826c0","added_by":"auto","created_at":"2024-03-15 12:01:40","extension":"png","order_by":10,"title":"Figure 10","display":"","copyAsset":false,"role":"figure","size":342594,"visible":true,"origin":"","legend":"\u003cp\u003e(A) Evolution of the average roughness (R\u003csub\u003ea\u003c/sub\u003e) as a function of passes (B) effect of cutting speed on the surface roughness of AISI D2 steel in the parameters R\u003csub\u003ea\u003c/sub\u003e, R\u003csub\u003ez \u003c/sub\u003eand R\u003csub\u003et \u003c/sub\u003e- interrupted cutting\u003c/p\u003e","description":"","filename":"figure10.png","url":"https://assets-eu.researchsquare.com/files/rs-4059612/v1/0e9aa31c0087870960511785.png"},{"id":65628092,"identity":"23d5c55e-de50-4ef8-a2d6-fc2e64b4c881","added_by":"auto","created_at":"2024-09-30 16:18:01","extension":"pdf","order_by":0,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":103789001,"visible":true,"origin":"","legend":"","description":"","filename":"manuscript.pdf","url":"https://assets-eu.researchsquare.com/files/rs-4059612/v1/297af6d0-99cf-481f-9a77-3997a925ffb8.pdf"}],"financialInterests":"","formattedTitle":"\u003cp\u003eEvaluation of the Performance of a Pcbn Tool in Turning Aisi D2 Hardened Steel in Continuous and Interrupted Cutting\u003c/p\u003e","fulltext":[{"header":"1. Introduction","content":"\u003cp\u003eThe turning of hardened steels has been widely applied in the industry due to its favorable outcomes compared to other processes, such as grinding, particularly in the automotive and molds and dies industries. Furthermore, it allows manufacturers to execute their processes in a simplified manner and achieve good results in terms of quality and surface integrity [\u003cspan citationid=\"CR1\" class=\"CitationRef\"\u003e1\u003c/span\u003e]. To ensure this, the equipment must possess characteristics that guarantee satisfactory machining, such as dynamic stability to prevent disturbances that may affect the operation, leading, for instance, to excessive vibration, play in the stroke, and sufficient power to meet the required cutting parameters [\u003cspan citationid=\"CR2\" class=\"CitationRef\"\u003e2\u003c/span\u003e].\u003c/p\u003e \u003cp\u003eThe processes employed in finishing operations on hardened materials were traditionally carried out using abrasive methods such as grinding or electrical discharge machining (EDM) [\u003cspan citationid=\"CR3\" class=\"CitationRef\"\u003e3\u003c/span\u003e]. Due to technological advancements, which have enhanced the rigidity and dynamic stability of machine tools, coupled with improvements in the materials of cutting tools characterized by high hardness and resistance to wear at elevated temperatures, machining of these materials has become feasible through turning processes [\u003cspan citationid=\"CR4\" class=\"CitationRef\"\u003e4\u003c/span\u003e]. According to [\u003cspan citationid=\"CR5\" class=\"CitationRef\"\u003e5\u003c/span\u003e], hard turning can produce workpieces with surface finishes comparable to those achieved through grinding.\u003c/p\u003e \u003cp\u003eA diverse range of tool materials, such as cemented carbide, ceramics, polycrystalline diamond (PCD), and cubic boron nitride (CBN), finds extensive use in the machining of hardened materials. The latter is identified as a global trend and considered the optimal choice [\u003cspan citationid=\"CR6\" class=\"CitationRef\"\u003e6\u003c/span\u003e]. This trend is attributed to its superior thermal conductivity and hardness when compared to other tool materials.\u003c/p\u003e \u003cp\u003eIn hard turning processes, small cutting depths are employed due to the hardness of the materials being machined. Typically, these cutting depth values are equal to or smaller than the radius of the insert tip [\u003cspan citationid=\"CR1\" class=\"CitationRef\"\u003e1\u003c/span\u003e].\u003c/p\u003e \u003cp\u003eAuthors [\u003cspan citationid=\"CR7\" class=\"CitationRef\"\u003e7\u003c/span\u003e] compared a conventional insert with others with straightening edge geometry to observe the behavior of the output parameters when machining heat-treated AISI D2 steel with two hardness values (55 and 60 HRC).\u003c/p\u003e \u003cp\u003eIn the work of [\u003cspan citationid=\"CR8\" class=\"CitationRef\"\u003e8\u003c/span\u003e], the performance and wear mechanisms were analyzed in a PCBN cutting tool in the turning of dry-machined AISI D2 hardened steel. In addition to high hardness (40-60HRC), cutting parameters such as cutting speed of 250 m/min, feed of 0.1 mm/ rev and a constant cutting depth of 0.15 mm were applied. As a result, they observed that flank wear increases linearly with increasing hardness of AISI D2 steel.\u003c/p\u003e \u003cp\u003eWhile turning of hardened steel demonstrates several advantages over the grinding process, it cannot be asserted that this method replaces all practical operations on grinders. This is because turning, grinding, and other abrasive finishing operations generate different surface structures that can influence their functional properties due to these distinct topographical characteristics [\u003cspan citationid=\"CR9\" class=\"CitationRef\"\u003e9\u003c/span\u003e].\u003c/p\u003e \u003cp\u003eThe study of surface and subsurface characteristics of materials obtained through machining processes, such as microhardness, residual stress analysis, roughness, and phase transformation, becomes crucial in the pursuit and understanding of the phenomena involved in the process, as well as in reducing final component failures. The performance of these components is highly dependent on the characteristics and properties of the final surfaces achieved [\u003cspan citationid=\"CR10\" class=\"CitationRef\"\u003e10\u003c/span\u003e].\u003c/p\u003e \u003cp\u003eTool wear can stem from two primary sources: thermal or mechanical factors. The wear mechanisms associated with tool wear are categorized into abrasion, oxidation, attrition, and diffusion. A comprehensive analysis of wear mechanisms is very important for interpreting behavior and understanding the dynamic interaction between the tool and the chip [\u003cspan citationid=\"CR11\" class=\"CitationRef\"\u003e11\u003c/span\u003e].\u003c/p\u003e \u003cp\u003eSurface roughness is the most commonly visible result of any machining processes that can be used to characterize process quality as it determines the functional properties of machined components. This occurs because surface roughness alters contact tribology, which is key to processes ranging from wear, adhesion to friction, lubrication, and coating systems [\u003cspan citationid=\"CR12\" class=\"CitationRef\"\u003e12\u003c/span\u003e]. This, in turn, influences the fatigue resistance, creep resistance, corrosion resistance and service life of the machined component. Therefore, adapting and controlling the roughness of the machined surface to a high level of precision is a fundamental requirement for many relevant applications [\u003cspan citationid=\"CR13\" class=\"CitationRef\"\u003e13\u003c/span\u003e].\u003c/p\u003e \u003cp\u003eIn this study, the performance of a PCBN tool with 75% by volume of CBN bonded to a Titanium (Ti) matrix was investigated in turning AISI D2 hardened steel under continuous and interrupted cutting conditions. The objective of this work is to analyze the behavior of wear mechanisms and evaluate the influence of variation in cutting speed and its correlation with surface roughness. Furthermore, to study whether the percentage of CBN content, as well as the binding material, influenced the resistance to abrasion and impact when machining of hardened tool steels.\u003c/p\u003e"},{"header":"2. Experimental Procedure","content":"\u003cp\u003eThe machined material was prepared in the form of \u0026Oslash;150 x 60 mm billets, coming from the same bar. The first operation carried out was pre -machining to prepare these materials. The machine tool used was a conventional ROMI lathe, model T-240, for machining the central holes and external diameters. Then, with the aid of wire electro-erosion machining, transversal cuts were made, reducing them to thicknesses close to the final measurements of the test piece. This process does not interfere, through thermal mechanisms, in the mechanical properties of the samples, unlike other conventional machining processes in which shear stresses are introduced. After this process, the discs were machined again on both sides, to remove the altered surface layer (white layer) for heat treatments. These were carried out in a salt bath oven with a capacity of \u0026Oslash;770 x 1400 mm.\u003c/p\u003e \u003cp\u003eThe tempering process initially occurred by heating the samples to 1020 \u0026ordm;C for 30 minutes. Then cooling to a temperature of 500 \u0026ordm;C for the first tempering for about 3 hours. Two more tempers were also carried out, both at 500 \u0026ordm;C for a period of 3 hours.\u003c/p\u003e \u003cp\u003eA sample of AISI D2 steel was characterized using optical emission spectrometry using the SPECTROMAXx spectrometer, to verify its chemical composition. To evaluate microstructural changes, samples were prepared, embedded in resin, and etched with Vilella for approximately 20 seconds. The evaluation was carried out with the aid of an OLYMPUS GX51 optical microscope. A hardness test on the Rockwell C scale was also carried out with the Dura Visio DV30 universal hardness tester before and after heat treatments.\u003c/p\u003e \u003cp\u003eThe machine used for turning is a CNC lathe with a nominal available power of 7.5 kW, maximum rotation of 3500 RPM.\u003c/p\u003e \u003cp\u003eTo fix the specimens in the machine, it was necessary to machine jaws to create a support stop to facilitate correct fitting and depth adjustment, given that the disc format is used in research in facing operations.\u003c/p\u003e \u003cp\u003eThe inserts used had the ISO DCGW 11T304S14N-OAB-PCBN geometry. The CBN raw material used was of the compact class of BZN 9000. It has a high volume in percentage of CBN, around 75% volume in the matrix based on Titanium (Ti). It has an average particle size of 4\u0026micro;m.\u003c/p\u003e \u003cp\u003eThe tool holder used was SDJCL 2020K 11, with position angle (93\u0026ordm;), tool attack angle (\u0026minus;\u0026thinsp;3\u0026ordm;), orthogonal exit angle (0\u0026ordm;), inclination angle (0\u0026ordm;), tool body angle in in relation to the machine (0\u0026ordm;), and angle of the tool body in relation to the part (0\u0026ordm;).\u003c/p\u003e \u003cp\u003eThe geometry of the test piece is disc-shaped, containing a through hole in its center, as shown in Fig.\u0026nbsp;\u003cspan refid=\"Fig1\" class=\"InternalRef\"\u003e1\u003c/span\u003e. This geometry induces greater rigidity due to reduced cantilever lengths. For the interrupted cut, tears were made on the face.\u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003cp\u003eOnce the specimens were prepared, external dry turning began in successive passes in the radial direction (facing) for both continuous and interrupted cutting. Five passes of 0.2 mm cutting depth (ap) were made, totaling 1 mm of material removed for each determined cutting speed range (60, 130, 200 and 240 m/min). In each track, a new tool was selected. The feed was kept the same for all experiments f\u0026thinsp;=\u0026thinsp;0.15 mm/rev. The surface finish of the machined part was measured using a roughness meter, taking measurements at three different points and the parameters R\u003csub\u003ea\u003c/sub\u003e, R\u003csub\u003ez\u003c/sub\u003e and R\u003csub\u003et\u003c/sub\u003e.\u003c/p\u003e \u003cp\u003eIn analyzing tool wear, a USB digital microscope was used to measure pass after pass. After the tests, to evaluate the final state of the inserts, the samples were evaluated using a scanning electron microscope (SEM). The samples were enlarged focusing on the region where the wear occurred, thus being able to verify the mechanisms suffered by the tools. In addition, energy dispersive spectroscopy (EDS) analyzes were carried out to chemically evaluate the final state of the tools in the region where the wear occurred.\u003c/p\u003e"},{"header":"3. Results and discussion","content":"\u003cdiv id=\"Sec4\" class=\"Section2\"\u003e \u003ch2\u003e3.1. Analysis of Chemical, Metallographic and Hardness Composition\u003c/h2\u003e \u003cp\u003eThe result of the chemical analysis, obtained by optical emission spectrometry, is presented in Table\u0026nbsp;\u003cspan refid=\"Tab1\" class=\"InternalRef\"\u003e1\u003c/span\u003e.\u003c/p\u003e \u003cp\u003e \u003cdiv class=\"gridtable\"\u003e\u003ctable float=\"Yes\" id=\"Tab1\" border=\"1\"\u003e \u003ccaption language=\"En\"\u003e \u003cdiv class=\"CaptionNumber\"\u003eTable 1\u003c/div\u003e \u003cdiv class=\"CaptionContent\"\u003e \u003cp\u003eChemical composition (wt.%)\u003c/p\u003e \u003c/div\u003e \u003c/caption\u003e \u003ccolgroup cols=\"5\"\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c1\" colnum=\"1\"\u003e\u003c/div\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c2\" colnum=\"2\"\u003e\u003c/div\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c3\" colnum=\"3\"\u003e\u003c/div\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c4\" colnum=\"4\"\u003e\u003c/div\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c5\" colnum=\"5\"\u003e\u003c/div\u003e \u003cthead\u003e \u003ctr\u003e \u003cth align=\"left\" colname=\"c1\"\u003e \u003cp\u003eCarbon\u003c/p\u003e \u003cp\u003e(C)\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c2\"\u003e \u003cp\u003eManganese (Mn)\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c3\"\u003e \u003cp\u003eChrome\u003c/p\u003e \u003cp\u003e(Cr)\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c4\"\u003e \u003cp\u003eMolybdenum (Mo)\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c5\"\u003e \u003cp\u003eVanadium\u003c/p\u003e \u003cp\u003e(V)\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003c/thead\u003e \u003ctbody\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e1.58\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003e0.32\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c3\"\u003e \u003cp\u003e11.67\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c4\"\u003e \u003cp\u003e0.68\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c5\"\u003e \u003cp\u003e0.83\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003c/tbody\u003e \u003c/colgroup\u003e \u003c/table\u003e\u003c/div\u003e \u003c/p\u003e \u003cp\u003eThe values found are consistent with those established through normative regulation. Figure\u0026nbsp;\u003cspan refid=\"Fig2\" class=\"InternalRef\"\u003e2\u003c/span\u003e shows the microstructure of AISI D2 steel in its normalized state, without undergoing heat treatment of quenching and tempering at 200x magnification and Vilella reactive.\u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003cp\u003eNote the presence of ferrite and carbides, characteristic of this type of steel, due to its chemical composition, where, through the alloying elements, they promote the presence of carbides in the microstructure. After carrying out the final treatments, the microstructure is obtained, which can be seen in Fig.\u0026nbsp;\u003cspan refid=\"Fig3\" class=\"InternalRef\"\u003e3\u003c/span\u003e.\u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003cp\u003eIt is possible to observe the predominant presence of martensite throughout the analyzed region, formed from tempering, in addition to a large proportion of carbides characteristic of this material.\u003c/p\u003e \u003cp\u003eRegarding hardness analysis, an average value of 15 HRC is found in the normalized state, this value being typically found in this type of steel without heat treatment. In relation to the values found after quenching and tempering heat treatment, the average value found was 60 HRC, reaching the initially established objective.\u003c/p\u003e \u003c/div\u003e \u003cdiv id=\"Sec5\" class=\"Section2\"\u003e \u003ch2\u003e3.2. Analysis of Wear on Cutting Tools and Mechanisms\u003c/h2\u003e \u003cp\u003eNext, the results of the maximum flank wear (VB\u003csub\u003ebm\u0026aacute;x\u003c/sub\u003e ) and the analysis of the mechanisms in each cutting speed range in the two machined conditions are presented. In Fig.\u0026nbsp;\u003cspan refid=\"Fig4\" class=\"InternalRef\"\u003e4\u003c/span\u003e, the evolution of VB\u003csub\u003ebm\u0026aacute;x\u003c/sub\u003e is presented as a function of the machined length (l\u003csub\u003ef\u003c/sub\u003e ) for the cutting speed curves in continuous and interrupted cutting conditions.\u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003cp\u003eIn the analysis for continuous cutting at a cutting speed of 60 m/min, values are observed only from l \u003csub\u003ef\u003c/sub\u003e = 200 mm, having VB\u003csub\u003ebmax\u003c/sub\u003e = 0.19 mm and reaching a maximum value of 0.23 mm at the end of the passes. Regarding the cutting speed curve of 130 m/min, it was only possible to measure from 150 mm of machined length, starting with VB\u003csub\u003ebmax\u003c/sub\u003e = 0.07 mm, with a maximum wear value of 0.15 mm in l \u003csub\u003ef\u003c/sub\u003e = 250mm. In the cutting speed range of 200 m/min, only at the machined length of 200 mm, the VB\u003csub\u003ebmax\u003c/sub\u003e was 0.09 mm and maintained this value until the last pass. The evolution of maximum flank wear for \u003csub\u003eVc\u003c/sub\u003e = 240 m/min presented values from the first pass of 0.06 mm, until reaching the maximum value of VB\u003csub\u003ebmax\u003c/sub\u003e = 0.28 mm.\u003c/p\u003e \u003cp\u003eIn interrupted cutting, in the cutting speed range of 60 m/min, it was not possible to carry out any measurements due to a catastrophic failure in the first instant of cutting. At 130 m/min, wear is measured only in the first pass (l\u003csub\u003ef\u003c/sub\u003e = 50 mm), as the tool failed in the next machined length. It was not possible to measure wear on the machined length of 250 mm in any of the cutting speed ranges, due to previous breaks and catastrophic failures.\u003c/p\u003e \u003cp\u003eAssessments using scanning electron microscopy (SEM) are described in the next figures. In Fig.\u0026nbsp;\u003cspan refid=\"Fig5\" class=\"InternalRef\"\u003e5\u003c/span\u003e, the final state of the tool in continuous cutting at cutting speeds of 60 m/min (A) and 130 m/min (B) is shown.\u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003cp\u003eAt \u003csub\u003eVc\u003c/sub\u003e at 60 m/min (A), it is possible to notice a detachment of material from the tool's exit surface and significant flank wear. The relative movement between the part and the tool promoted the detachment of both the adhered material itself and small particles from the tool. This situation characterizes the attrition mechanism that occurs at low cutting speeds and lower temperatures. An energy dispersive X-ray spectroscopy (EDS) coupled to (SEM) was carried out at a cutting speed of 60 m/min, which is presented in Table\u0026nbsp;\u003cspan refid=\"Tab2\" class=\"InternalRef\"\u003e2\u003c/span\u003e. The result of the analysis showed the presence of elements such as Iron (Fe), Chromium (Cr) and Molybdenum (Mo) match the chemical composition of the machined specimen, characterizing material adhered to the tool.\u003c/p\u003e \u003cp\u003eWhen analyzing \u003csub\u003eVc\u003c/sub\u003e at 130 m/min (B), the presence of crater and flank wear was observed. From this speed range onwards, there was a change in the wear mechanism. Abrasion contributed to both types of wear, and in addition, the diffusion mechanism is highlighted due to the evidence of a smooth surface inside the crater, characteristic of the diffusive process. The results closely resemble those observed in other studies [\u003cspan citationid=\"CR14\" class=\"CitationRef\"\u003e14\u003c/span\u003e], [\u003cspan citationid=\"CR15\" class=\"CitationRef\"\u003e15\u003c/span\u003e] e [\u003cspan citationid=\"CR2\" class=\"CitationRef\"\u003e2\u003c/span\u003e].\u003c/p\u003e \u003cp\u003e \u003cdiv class=\"gridtable\"\u003e\u003ctable float=\"Yes\" id=\"Tab2\" border=\"1\"\u003e \u003ccaption language=\"En\"\u003e \u003cdiv class=\"CaptionNumber\"\u003eTable 2\u003c/div\u003e \u003cdiv class=\"CaptionContent\"\u003e \u003cp\u003e-The Energy Dispersive Spectroscopy (EDS) continuous cutting V\u003csub\u003ec\u003c/sub\u003e = 60 m/min\u003c/p\u003e \u003c/div\u003e \u003c/caption\u003e \u003ccolgroup cols=\"12\"\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c1\" colnum=\"1\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c2\" colnum=\"2\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c3\" colnum=\"3\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c4\" colnum=\"4\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c5\" colnum=\"5\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c6\" colnum=\"6\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c7\" colnum=\"7\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c8\" colnum=\"8\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c9\" colnum=\"9\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c10\" colnum=\"10\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c11\" colnum=\"11\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c12\" colnum=\"12\"\u003e\u003c/div\u003e \u003cthead\u003e \u003ctr\u003e \u003cth align=\"left\" colname=\"c1\"\u003e \u003cp\u003eRegions\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c2\"\u003e \u003cp\u003eC\u003c/p\u003e \u003cp\u003e(%)\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c3\"\u003e \u003cp\u003eO\u003c/p\u003e \u003cp\u003e(%)\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c4\"\u003e \u003cp\u003eTi\u003c/p\u003e \u003cp\u003e(%)\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c5\"\u003e \u003cp\u003eAl\u003c/p\u003e \u003cp\u003e(%)\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c6\"\u003e \u003cp\u003eSi\u003c/p\u003e \u003cp\u003e(%)\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c7\"\u003e \u003cp\u003eCr\u003c/p\u003e \u003cp\u003e(%)\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c8\"\u003e \u003cp\u003eV\u003c/p\u003e \u003cp\u003e(%)\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c9\"\u003e \u003cp\u003eW\u003c/p\u003e \u003cp\u003e(%)\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c10\"\u003e \u003cp\u003eFe\u003c/p\u003e \u003cp\u003e(%)\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c11\"\u003e \u003cp\u003eN\u003c/p\u003e \u003cp\u003e(%)\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c12\"\u003e \u003cp\u003eMo\u003c/p\u003e \u003cp\u003e(%)\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003c/thead\u003e \u003ctbody\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003eInclusion 1\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e18,92\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e17,93\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e19,76\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c5\"\u003e \u003cp\u003e19,95\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c6\"\u003e\u0026nbsp;\u003c/td\u003e \u003ctd align=\"left\" colname=\"c7\"\u003e\u0026nbsp;\u003c/td\u003e \u003ctd align=\"left\" colname=\"c8\"\u003e\u0026nbsp;\u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c9\"\u003e \u003cp\u003e7,64\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c10\"\u003e \u003cp\u003e1,45\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c11\"\u003e \u003cp\u003e18,29\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c12\"\u003e\u0026nbsp;\u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003eInclusion 2\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e17,12\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e5,51\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e0,16\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c5\"\u003e \u003cp\u003e0,21\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c6\"\u003e \u003cp\u003e0,43\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c7\"\u003e \u003cp\u003e10,70\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c8\"\u003e \u003cp\u003e0,67\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c9\"\u003e\u0026nbsp;\u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c10\"\u003e \u003cp\u003e63,67\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c11\"\u003e\u0026nbsp;\u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c12\"\u003e \u003cp\u003e0,81\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003c/tbody\u003e \u003c/colgroup\u003e \u003c/table\u003e\u003c/div\u003e \u003c/p\u003e \u003cp\u003eIn Fig.\u0026nbsp;\u003cspan refid=\"Fig7\" class=\"InternalRef\"\u003e7\u003c/span\u003e, the final state of the tool is shown in continuous cutting at cutting speeds of 200 m/min (A) and 240 m/min (B). In the range of 200 m/min the tool behaved satisfactorily until the penultimate pass. In general, the wear that occurs does not come from just one mechanism, but rather from a combination of several of them. The large number of carbides present and the resistance to high temperatures in hardened AISI D2 steel caused, in most of the cutting speeds studied, intense wear resulting in a reduced lifetime. Diffusion and abrasion mechanisms probably occurred, as they caused a considerable crater on the exit surface and the chipping process occurred in the last pass.\u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003cp\u003eIn the test with a cutting speed of 240 m/min (highest value range recommended by the manufacturer), the tool behaved satisfactorily, especially when working with a new edge and in the subsequent pass. As can be seen, crater wear caused by abrasion mechanisms followed by diffusion was once again predominant, in addition to flank wear. According to [\u003cspan citationid=\"CR16\" class=\"CitationRef\"\u003e16\u003c/span\u003e], [\u003cspan citationid=\"CR17\" class=\"CitationRef\"\u003e17\u003c/span\u003e], the high temperatures present in the cutting region tend to stimulate the two mechanisms. This is because the removal of fragments from the tool by abrasion favors the exchange of particles between tool and chip (diffusion). No cracks or chips were identified.\u003c/p\u003e \u003cp\u003eIn the analyzes carried out for interrupted cutting, initially the cutting speeds of 60m/min and 130m/min behaved unsatisfactorily. In the first moments of cutting, the tool failed. The severe tribological condition, followed by the greater number of inputs and outputs, caused the tool to fail, unable to withstand the impacts of interrupted cutting. The toughness and hardness of the tool were not able to withstand these efforts driven by low cutting speeds. Figure\u0026nbsp;\u003cspan refid=\"Fig8\" class=\"InternalRef\"\u003e8\u003c/span\u003e shows the tools after the end of the tests.\u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003cp\u003eIn tests with the tool at higher cutting speeds (Fig.\u0026nbsp;\u003cspan refid=\"Fig9\" class=\"InternalRef\"\u003e9\u003c/span\u003e), there was a slightly more satisfactory performance than previous results. At \u003csub\u003eVc\u003c/sub\u003e = 200 m/min, the test was carried out until the machined length was 200 mm, culminating in the last pass with the insert breaking. In the indication of the highest cutting speed range indicated by the manufacturer in \u003csub\u003eVc\u003c/sub\u003e = 240 m/min, the tool managed to reach only 150 mm of machined length, culminating in catastrophic failure.\u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003c/div\u003e \u003cdiv id=\"Sec6\" class=\"Section2\"\u003e \u003ch2\u003e3.3. Roughness Analysis\u003c/h2\u003e \u003cp\u003eTo evaluate the surface finish, the evolution of surface roughness was analyzed, comparing it in some aspects, such as the influence of cutting speed as a function of machining lengths, in continuous and interrupted cutting conditions. Although it is known that advancement is the most influential parameter in surface finishing [\u003cspan citationid=\"CR18\" class=\"CitationRef\"\u003e18\u003c/span\u003e], other conditions affect surface quality and must be evaluated for a better understanding of the process [\u003cspan citationid=\"CR19\" class=\"CitationRef\"\u003e19\u003c/span\u003e].\u003c/p\u003e \u003cp\u003eInitially, when observing the influence of cutting speed on the roughness of AISI D2 steel in continuous cutting, in the last pass (Fig.\u0026nbsp;\u003cspan refid=\"Fig10\" class=\"InternalRef\"\u003e10\u003c/span\u003e-A), a similar behavior was noted in the three parameters evaluated. There was initially a reduction in roughness values at a cutting speed of 130 m/min compared to speeds of 60 m/min, 200 m/min and 240 m/min. In the two largest \u003csub\u003eVc\u003c/sub\u003e, there was little variation in the results, showing a stable range for the continuous cutting condition. When evaluating the average roughness (R\u003csub\u003ea\u003c/sub\u003e) (Fig.\u0026nbsp;\u003cspan refid=\"Fig10\" class=\"InternalRef\"\u003e10\u003c/span\u003e-B), a better result is indicated for the cutting speed range of 130 m/min, which reached a value of R\u003csub\u003ea\u003c/sub\u003e = 0.416 \u0026micro;m, a favorable condition for finishing operations and which can be used to characterize machining quality, as it determines the functional properties of a machined component [\u003cspan citationid=\"CR20\" class=\"CitationRef\"\u003e20\u003c/span\u003e].\u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003cp\u003eIn the analysis of the interrupted cutting condition presented in Fig.\u0026nbsp;11 (A), the cutting speed range of 60 m/min does not appear in the graphs, as it was not possible to measure the roughness due to the break that occurred at the beginning of the cut. It is noted that the cutting speed range that obtained the lowest roughness evaluated was 240 m/min, with a value of R \u003csub\u003ea\u003c/sub\u003e = 0.549 \u0026micro;m in the second pass, and the highest roughness measured occurred with a cutting speed of 200 m/min in the last pass, with a value of 1.013 \u0026micro;m. From the second pass onwards, there were no roughness values for the range of 130 m/min, as the tool suffered breakage, preventing the continuation of the test. Also, there were no values for the 240 m/min range, starting from the fourth pass for the same reason. It was observed that the increase in cutting speed did not significantly influence the surface roughness values for the tool with the new edge. Therefore, in this range (130 to 240 m/min) the increase in cutting speed has little effect on surface quality when it comes to new tools. In general, roughness is increased by the evolution of wear. Figure\u0026nbsp;11 (B) shows an evaluation of only the first pass of the three roughness parameters evaluated. There was no significant difference in the ranges of \u003csub\u003eVc\u003c/sub\u003e = 130, 200 and 240 m/min.\u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003c/div\u003e"},{"header":"4. Conclusion","content":"\u003cp\u003eThe greatest evidence of wear that occurred in the continuous cut was crater and flank. As well as chipping and catastrophic failure in interrupted cutting. The wear mechanisms highlighted were adhesion and pullout (attrition), abrasion and diffusion.\u003c/p\u003e\n\u003cp\u003eWith the increase in cutting speed, a change in the wear mechanism in continuous cutting was observed, going from \u003cem\u003eattrition\u0026nbsp;\u003c/em\u003e(\u003csub\u003eVc\u0026nbsp;\u003c/sub\u003e= 60 m/min) to abrasion and diffusion (\u003csub\u003eVc\u0026nbsp;\u003c/sub\u003e= 130, 200 and 240 m/min), converging with information available in literature.\u003c/p\u003e\n\u003cp\u003eThe increase in cutting speed resulted in the expected increase in tool wear. In continuous cutting, the tool presented a more satisfactory performance, reaching 250 mm in machined length at all selected cutting speeds.\u003c/p\u003e\n\u003cp\u003eWhen comparing cutting conditions, the highest measured value of VB\u003csub\u003ebmax\u0026nbsp;\u003c/sub\u003ewas 0.61 mm in interrupted cutting at 200 m/min. In the same range and machined length, a value of 0.09 mm was recorded in continuous cutting, which represents an increase of 6.7 times.\u003c/p\u003e\n\u003cp\u003eIn the cutting speed range of 130 m/min in continuous cutting, an average roughness (R\u003csub\u003ea\u003c/sub\u003e) of 0.416\u0026micro;m was measured. This highly favorable result can be equivalent to rectification operations, making it viable to replace this process in certain situations.\u003c/p\u003e\n\u003cp\u003eThe tests showed that flank wear does not necessarily result in an increase in roughness, and, as it settles over a certain cutting time, the surface quality improves.\u003c/p\u003e\n\u003cp\u003eThe tool did not perform satisfactorily at lower cutting speeds (60 m/min), both for continuous and interrupted cutting, suggesting better performance at higher values.\u003c/p\u003e\n\u003cp\u003eIn interrupted cutting, the higher cutting speeds resulted in longer tool life compared to the lower tested speeds of 60 m/min and 130 m/min.\u003c/p\u003e\n\u003cp\u003eThe BZN9000 class was not tough enough to withstand the impacts caused by interrupted cutting and is not suitable for this type of operation. On the other hand, for continuous cutting, the use of higher speeds has demonstrated positive results in terms of increased productivity.\u003c/p\u003e"},{"header":"Declarations","content":"\u003cp\u003e\u003cstrong\u003eCompeting interests\u003c/strong\u003e\u003c/p\u003e\n\u003cp\u003eThe authors Ernane Felipe Dias, Caio C\u0026eacute;sar Gon\u0026ccedil;alves Coutinho Barroso, and Sandro Cardoso Santos declare that they have no conflicts of interest or financial conflicts to disclose.\u003c/p\u003e\n\u003cp\u003e\u003cstrong\u003eAvailability of data and material\u0026nbsp;\u003c/strong\u003e\u003c/p\u003e\n\u003cp\u003eThe authors confirm that the data supporting the findings of this study are available within the article.\u003c/p\u003e\n\u003cp\u003e\u003cstrong\u003eCode availability\u0026nbsp;\u003c/strong\u003e\u003c/p\u003e\n\u003cp\u003eNot applicable\u003c/p\u003e\n\u003cp\u003e\u003cstrong\u003eEthical approval\u003c/strong\u003e\u003c/p\u003e\n\u003cp\u003eAll authors have previously approved this paper and judged that there is no ethical infringement.\u003c/p\u003e\n\u003cp\u003e\u003cstrong\u003eConsent to participate and publication\u003c/strong\u003e\u003c/p\u003e\n\u003cp\u003eAll authors would like to declare that they have approved their participation and consent about the publication in this journal.\u003c/p\u003e\n\u003cp\u003e\u003cstrong\u003eAuthor Contributions\u003c/strong\u003e\u003c/p\u003e\n\u003cp\u003e\u003cstrong\u003eErnane Felipe Dias\u003c/strong\u003e was responsible for the conceptualization, experimental work and writing of the manuscript. \u003cstrong\u003eCaio C\u0026eacute;sar Barroso\u003c/strong\u003e were contributed to experimental work and \u003cstrong\u003eSandro Cardoso\u003c/strong\u003e were responsible for the revision of the manuscript and contributed to the technical discussion of the results. \u003cstrong\u003eSandro Cardoso\u003c/strong\u003e was responsible for the supervision of the work and the availability of resources.\u003c/p\u003e\n\u003cp\u003e\u003cstrong\u003eAcknowledgements\u003c/strong\u003e\u003c/p\u003e\n\u003cp\u003eThis work was conducted with the support of the Federal Centre of Technological Education of Minas Gerais (CEFET-MG), SENAI Ita\u0026uacute;na CETEF Marcelino Corradi, SENAI Contagem Euvaldo Lodi, MAPAL Dr. Kress KG do Brazil, LCF Ind\u0026uacute;stria Mec\u0026acirc;nica Ltda. and Metaltemper Tratamentos T\u0026eacute;rmicos de Metais.\u003c/p\u003e"},{"header":"References","content":"\u003col\u003e\n \u003cli\u003eYousefi, S., Zohoor, M. Effect of cutting parameters on the dimensional accuracy and surface finish in the hard turning of MDN250 steel with cubic boron nitride tool, for developing a knowledge base expert system. Int J Mech Mater Eng, v. 14, 2019. https://doi-org.ez107.periodicos.capes.gov.br/10.1186/s40712-018-0097-7.\u003c/li\u003e\n \u003cli\u003eBoing, D.; Schroeter, RB; Oliveira, AJ. Three\u0026ndash; Dimensional Wear Parameters and Wear Mechanisms in Turning Hardened Steels with PCBN Tools. Wear, vol. 398\u0026ndash; 399, p. 69\u0026ndash; 78, 2018. https://doi.org/10.1016/j.wear.2017.11.017.\u003c/li\u003e\n \u003cli\u003eGopalsamy, B.M., Mondal, B., Ghosh, S. et al. Experimental investigations while hard machining of DIEVAR tool steel (50 HRC). The International Journal of Advanced Manufacturing Technology, v. 51, p. 853-869, 2010. https://doi.org/10.1007/s00170-010-2688-1.\u003c/li\u003e\n \u003cli\u003eLaw M, Karthik R, Sharma S, Ramkumar J. Finish turning of hardened bearing steel using textured PcBN tools. J Manuf Process v. 60, p. 144\u0026ndash;161, 2020. https://doi.org/10.1016/j.jmapro.2020.10.\u003c/li\u003e\n \u003cli\u003eGrzesik, W. Prediction of surface topography in precision hard machining based on modeling of the generation mechanisms resulting from a variable feed rate. International Journal of Advance Manufacturing Technology, vol. 94, p. 4115\u0026ndash; 4123, 2018. https://doi.org/10.1007/s00170-017-1129-9.\u003c/li\u003e\n \u003cli\u003eKumar, P.; Chauhan, S.R.; Pruncu, C.I.; Gupta, M.K.; Pimenov, D.Y.; Mia, M.; Gill, H.S. Influence of Different Grades of CBN Inserts on Cutting Force and Surface Roughness of AISI H13 Die Tool Steel during Hard Turning Operation. Materials, 12, 177, 2018. https://doi.org/10.3390/ma12010177.\u003c/li\u003e\n \u003cli\u003eSarmad Ali Khan, Muhammad Umar, Muhammad Qaiser Saleem, Nadeem Ahmad Mufti, Syed Farhan Raza, Experimental investigations on wiper inserts\u0026rsquo; edge preparation, workpiece hardness and operating parameters in hard turning of AISI D2 steel, Journal of Manufacturing Processes, v. 34, p 187-196, 2018. https://doi.org/10.1016/j.jmapro.2018.06.004.\u003c/li\u003e\n \u003cli\u003eLinhu Tang, Yongji Sun, Baodong Li, Jiancheng Shen, Guoliang Meng, Wear performance and mechanisms of PCBN tool in dry hard turning of AISI D2 hardened steel, Tribology International, v. 132, p. 228-236, 2019. https://doi.org/10.1016/j.triboint.2018.12.026.\u003c/li\u003e\n \u003cli\u003eGrzesik, W., Rech, J. \u0026amp; Żak, K. Characterization of surface textures generated on hardened steel parts in high-precision machining operations. 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Ultraprecision Micro Grooving on Brass for Surface Wettability Control. AMR. v. 1017, p. 489\u0026ndash;94, 2014. https://doi.org/10.4028/www.scientific.net/amr.1017.489.\u003c/li\u003e\n \u003cli\u003eLima, J.G, R.F. \u0026Aacute;vila, A.M. Abr\u0026atilde;o, M. Faustino, J. Paulo Davim, Hard turning: AISI 4340 high strength low alloy steel and AISI D2 cold work tool steel, Journal of Materials Processing Technology, v. 169, p. 388-395, 2005. https://doi.org/10.1016/j.jmatprotec.2005.04.082.\u003c/li\u003e\n \u003cli\u003eRajashree M, Ramanuj K, Amlana P, Ashok K.S. Hard Turning Performance Evaluation Using Cvd And Pvd Coated Carbide Tools: A Comparative Study. Surface Review and Letters, v. 29, n. 2, 2022. https://doi.org/10.1142/S0218625X22500202.\u003c/li\u003e\n \u003cli\u003eDe Oliveira, A.J., Boing, D., Schroeter, R.B. Effect of PCBN tool grade and cutting type on hard turning of high-chromium white cast iron. Int J Adv Manuf Technol. v. 82, p. 797\u0026ndash;807, 2016. https://doi-org./10.1007/s00170-015-7426-2.\u003c/li\u003e\n \u003cli\u003eDiniz, A.E., Oliveira, A.J. Hard turning of interrupted surfaces using CBN tools, Journal of Materials Processing Technology,v. 195,p. 275-281, 2008. https://doi.org/10.1016/j.jmatprotec.2007.05.022.\u003c/li\u003e\n \u003cli\u003eManoj, N, Rakesh, S, Rajender, K. Investigating machinability of AISI D6 tool steel using CBN tools during hard turning, Materials Today: Proceedings, v. 47, p. 3960-3965, 2021, https://doi.org/10.1016/j.matpr.2021.04.020.\u003c/li\u003e\n \u003cli\u003eMachado, \u0026Aacute;. R.; Abr\u0026atilde;o, A. M.; Coelho, R. T.Silva, M. B. D. (2018) Teoria da usinagem dos materiais. Blucher, 3\u0026ordf; Edi\u0026ccedil;\u0026atilde;o.\u003c/li\u003e\n \u003cli\u003eAnupam, A., Saurav, G., Waleed, B. R., Mark, P.,Prediction of surface roughness during hard turning of AISI 4340 steel (69 HRC), Applied Soft Computing, v. 30, p .279-286, 2015. https://doi.org/10.1016/j.asoc.2015.01.059.\u003c/li\u003e\n\u003c/ol\u003e"}],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":true,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":false,"highlight":"","institution":"","isAcceptedByJournal":true,"isAuthorSuppliedPdf":false,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":false,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"the-international-journal-of-advanced-manufacturing-technology","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jamt","sideBox":"Learn more about [The International Journal of Advanced Manufacturing Technology](https://www.springer.com/journal/170)","snPcode":"170","submissionUrl":"https://submission.nature.com/new-submission/170/3","title":"The International Journal of Advanced Manufacturing Technology","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false},"keywords":"Hard Turning. PCBN Tool. Tool Wear. AISI D2 steel. Roughness","lastPublishedDoi":"10.21203/rs.3.rs-4059612/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-4059612/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eImportant technological advances in the mechanical manufacturing industry have increasingly generated good results with the turning of hardened materials, using polycrystalline cubic boron nitride (PCBN) tools, mainly replacing abrasive processes. Tool steels play varied and essential roles in various industrial applications, such as dies and punches for forming and cutting. This work involves the evaluation the performance of a PCBN tool in turning quenched and tempered AISI D2 steel, both in continuous cutting and interrupted cutting conditions, in the finishing operation with dry machining. The surface roughness was evaluated in the parameters (R\u003csub\u003ea\u003c/sub\u003e, R\u003csub\u003et\u003c/sub\u003e and R\u003csub\u003ez\u003c/sub\u003e), the wear suffered by the tools, their mechanisms and morphological analysis of the chips. Tests were carried out with different cutting speeds (60, 130, 200 and 240 m/min), maintaining a constant feed rate of 0.15 mm/rev and a cutting depth of 0.2 mm. The results indicated that the most evident wear was crater and flank in the continuous cut, while in the interrupted cut there was the presence of chipping and catastrophic failure. Wear mechanisms, such as adhesion (attrition), abrasion and diffusion were prominently observed. Furthermore, the tests showed that the increase in flank wear did not necessarily result in an increase in surface roughness, and that the wear mechanism changed with the increase in cutting speed. In the continuous cutting condition, the tool achieved more satisfactory performance, especially at higher cutting speeds (130, 200 and 240 m/min). In interrupted cutting, there is a predominance of catastrophic failure mainly in the ranges of 60 and 130 m/min and better performance at 200 m/min within the ranges evaluated.\u003c/p\u003e","manuscriptTitle":"Evaluation of the Performance of a Pcbn Tool in Turning Aisi D2 Hardened Steel in Continuous and Interrupted Cutting","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2024-03-15 12:01:35","doi":"10.21203/rs.3.rs-4059612/v1","editorialEvents":[{"type":"communityComments","content":0},{"type":"decision","content":"Major Revisions Needed","date":"2024-07-19T22:29:21+00:00","index":"","fulltext":""},{"type":"reviewerAgreed","content":"","date":"2024-04-05T22:04:37+00:00","index":0,"fulltext":""},{"type":"reviewersInvited","content":"","date":"2024-03-13T15:13:18+00:00","index":"","fulltext":""},{"type":"editorAssigned","content":"","date":"2024-03-12T05:57:56+00:00","index":"","fulltext":""},{"type":"submitted","content":"The International Journal of Advanced Manufacturing Technology","date":"2024-03-09T15:14:28+00:00","index":"","fulltext":""}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"the-international-journal-of-advanced-manufacturing-technology","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jamt","sideBox":"Learn more about [The International Journal of Advanced Manufacturing Technology](https://www.springer.com/journal/170)","snPcode":"170","submissionUrl":"https://submission.nature.com/new-submission/170/3","title":"The International Journal of Advanced Manufacturing Technology","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false}}],"origin":"","ownerIdentity":"0984fa50-8b25-4696-8da8-c827a9a8e532","owner":[],"postedDate":"March 15th, 2024","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"published-in-journal","subjectAreas":[],"tags":[],"updatedAt":"2024-09-30T16:10:18+00:00","versionOfRecord":{"articleIdentity":"rs-4059612","link":"https://doi.org/10.1007/s00170-024-14511-w","journal":{"identity":"the-international-journal-of-advanced-manufacturing-technology","isVorOnly":false,"title":"The International Journal of Advanced Manufacturing Technology"},"publishedOn":"2024-09-24 15:57:36","publishedOnDateReadable":"September 24th, 2024"},"versionCreatedAt":"2024-03-15 12:01:35","video":"","vorDoi":"10.1007/s00170-024-14511-w","vorDoiUrl":"https://doi.org/10.1007/s00170-024-14511-w","workflowStages":[]},"version":"v1","identity":"rs-4059612","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-4059612","identity":"rs-4059612","version":["v1"]},"buildId":"qtupq5eGEP_6zYnWcrvyt","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}