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Integration of heat treatment into the process chain of a mill turn center by enabling external cylindrical grind-hardening

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Abstract

The modern mill turn center enables the manufacturing of complex cylindrical parts on a single machine tool. In many cases, complete machining is inhibited by using conventional heat treatment processes, e.g. induction hardening, which cannot be included in the metal-cutting process chain. An innovative approach for surface hardening is the grind-hardening process, which uses the heat generated during material removal with geometrically undefined cutting edges to realize a martensitic phase transformation within the surface layer. This paper presents a methodology for applying the grind-hardening process to a conventional mill turn center. The process layout is supported using numerical methods, e.g. the finite element method. The recommended process strategy eliminates the process-specific hardness slip beneath the plunge zone area and allows for a repeatable process behavior. Thus, the methods presented within this paper support a sustainable industrialization of the grind-hardening process.

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Abbreviations

a e :

Depth of cut (mm)

a ed :

Depth of dressing cut (μm)

a e,pl :

Depth of plunge (μm)

b d :

Active width of dressing tool (mm)

b gw :

Grinding wheel width (mm)

B :

Rotatory axis of tool spindle (–)

c :

Specific heat capacity (J/kg K)

c wt :

Carbon content (weight %)

C i :

ith Workpiece spindle speed (min−1)

C i :

ith Rotatory axis of workpiece spindle (–)

d eq :

Equivalent grinding wheel diameter (mm)

d gw :

Grinding wheel diameter (mm)

d k :

Average grit size (μm)

d k :

Dressing rod width (μm)

d r :

Form roller diameter (mm)

d w :

Workpiece diameter (mm)

d w,e :

Finished workpiece diameter (mm)

d w,s :

Unfinished workpiece diameter (mm)

e ch :

Specific inner energy of the chips (J/mm3)

F :

Force (N)

FE :

Finite element (–)

h :

Heat transfer coefficient (W/mm2 K)

HPD :

Hardness penetration depth (–)

HPS :

Helical plunge strategy (–)

HV :

Hardness Vickers (–)

k :

Thermal conductivity (W/mm K)

l g :

Geometrical contact length (mm)

l g,pl :

Plunge contact length (mm)

l s :

Sacrificial material length (mm)

l s,min :

Minimum sacrificial material length (mm)

MQL :

Minimum quantity lubrication (–)

P c :

Grinding power (W)

P″ c :

Area related grinding power (W/mm2)

P t :

Tool spindle power (kW)

P w :

Workpiece spindle power (kW)

\(\dot q\) :

Heat flux density (W/mm2)

q d :

Dressing speed ratio (–)

Q cl :

Coolant volume flow rate (l/min)

Q w :

Material removal rate (mm3/s)

Q′ w :

Specific material removal rate (mm3/mm s)

RPS :

Radial plunge strategy (–)

S :

Safety or start position (–)

S i :

ith Tool spindle speed (min−1)

S i :

ith Rotatory axis of tool spindle (–)

t c :

Contact time (s)

t c,pl :

Plunge contact time (s)

T p :

Process temperature (°C)

T p,max :

Maximum process temperature (°C)

TPS :

Tangential plunge strategy (–)

U d :

Dressing overlap ratio (–)

v c :

Cutting speed (m/s)

v f,pl :

Plunge speed (m/s)

v s :

Grinding wheel circumferential speed (m/s)

v w :

Workpiece speed (m/min)

w :

Groove width (mm)

w total :

Total groove width (mm)

X i :

ith Translatory X-axis of mill turn center (–)

Y i :

ith Translatory Y-axis of mill turn center (–)

z :

Surface depth (mm)

Z i :

ith Translatory Z-axis of mill turn center (–)

ρ:

Density (kg/mm3)

\(\varphi_{feed}\) :

Feed angle (°)

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Acknowledgments

The results presented in this paper were gained in the course of a research and development project funded by DMG / Mori Seiki USA Technical Center Chicago. The novel methods and devices are covered in pending patents. The authors thank the Institute of Metal Forming and Casting (\({{\sl utg}}\)) at the Technische Universitaet Muenchen (TUM) for the opportunity to use the micro hardness test device. The authors are responsible for the contents of this publication.

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Authors and Affiliations

  1. DMG/Mori Seiki USA Technical Center Chicago, 2400 Huntington Boulevard, Hoffman Estates, IL, 60192, USA

    Gregory A. Hyatt

  2. Mori Seiki Co. Ltd., 2-35-16 Meieki, Nakamura-ku, Nagoya City, Aichi, 450-0002, Japan

    Masahiko Mori

  3. Institute for Machine Tools and Industrial Management (iwb), Technische Universitaet Muenchen, Boltzmannstr. 15, 85748, Garching, Germany

    Tobias Foeckerer & Michael F. Zaeh

  4. Laboratory for Machine Tools and Production Engineering (WZL), RWTH Aachen University, Steinbachstr. 19, 52074, Aachen, Germany

    Nils Niemeyer & Michael Duscha

Authors
  1. Gregory A. Hyatt
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  2. Masahiko Mori
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  3. Tobias Foeckerer
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  4. Michael F. Zaeh
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  5. Nils Niemeyer
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  6. Michael Duscha
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Corresponding author

Correspondence to Tobias Foeckerer.

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Hyatt, G.A., Mori, M., Foeckerer, T. et al. Integration of heat treatment into the process chain of a mill turn center by enabling external cylindrical grind-hardening. Prod. Eng. Res. Devel. 7, 571–584 (2013). https://doi.org/10.1007/s11740-013-0465-3

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  • DOI: https://doi.org/10.1007/s11740-013-0465-3

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