Annals of DAAAM for 2012 & Proceedings of the 23rd International DAAAM Symposium, Volume 23, No.

1, ISSN 2304-1382
ISBN 978-3-901509-91-9, CDROM version, Ed. B. Katalinic, Published by DAAAM International, Vienna, Austria, EU, 2012
Make Harmony between Technology and Nature, and Your Mind will Fly Free as a Bird
Annals & Proceedings of DAAAM International 2012

IMPROVING THE QUALITY OF THE MACHINING PROCESS

JAMBOR, J[aroslav]

Abstract: This paper describes the functional surfaces creation For finishing machining of hard materials such as
turned by the mixed cutting ceramics or coated carbide hardened steel was previously a problem due to the high
changeable insert. The hard turning process was realised by temperature process of cutting, high cutting parameters
CNC programming in FANUC MANUAL GUIDE i system at and non adequate system machine-tool-workpiece-
CNC machine tool. FANUC programming system contains from
software which make possible to create programme by CNC
fixture. Replacement of grinding by the turning tools
codes and graphically as in CAD/CAM methods joined together with coated cemented carbide and ceramic cutting inserts
into whole compact system. Automating the production process and automated production process with the support of
and the subsequent generation of NC code in ISO format is a CAE systems to achieve the desired quality of machined
developing trend in the series (mass) production. Significantly surface in a shorter manufacturing time and improved
reduces production time and the main side times, unlike accuracy of production [5]. This was realized in the CNC
conventional production machinery. Author solution is in the machining center with control system Manual Guide-i, in
shortened production process applied to HSC machining and cooperation with the MASH Integration Co. Trencin.
grinding rather than qualitative indicators improved surface
integrity. The first chapter is an introduction of paper defining
the fundamental points. The second and third chapter describes 2. GRINDING REPLACEMENT BY THE DRY
the grinding replacement by the CNC turning technology with HARD TURNING TECHNOLOGY
new cutting tools on practical examples and also experiments.
The last chapter is conclusion and recommendations to improve Arguably, the traditional grinding now reached the
the quality of machining. All this was practically demonstrated limits of their best options. Material removal volume is
in the research organization VSM - The School of Management small, hardened surface layers of ground dominated by
in Trencin, Slovakia in cooperation with MASH Integration Co. tensile stress components.
Trencin.
Keywords: hard turning, cutting parameters, quality process Unlike sanding or bush is turning shafts in the turbid
CNC programming, process improvement, hardened steel, state series advantages:
grinding
- Small machine investment costs,
1. INTRODUCTION - Short machining times,
- Shape and complex geometry of the workpiece to be
In recent years there has been significant implemented in a clamping,
development in Slovakia automotive industry. Much of - Smaller number of operational sections (steps) to the
components for the automotive industry is the result of Semi finished components,
mutual cooperation between companies engaged in car - No, the cost for disposal of sludge and abrasive
manufacturing and engineering firms to manufacture refrigerants, because hard turning is done mostly dry.
machine parts and components for automobile companies How hard turning negative sides to be addressed is:
using the technology of machining.
- Tool wear - to change the size and quality of surface,
It is turning and milling technology for CNC machine - Less reliable process,
tools using modern control systems with computerized - Strongly intermittent cuts are difficult.
CAD/CAM systems appears to be an important way of
improving the quality and precision manufactured The turning point grinding meet very high
components for the automotive industry [1]. requirements as mixed ceramic cutting - CC (Al2O3 +
TiCN) or CBN. High wear resistance, hot hardness
As the machined material, usually hardened steel combined with high compressive strength and chemical
have hardness greater than 45 HRC, but in general ranges stability and sufficient strength against breaking open,
of hardness 53 to 58 HRC, reaching a maximum of 65 crucially determine the quality of the finished piece [6].
HRC, talking about "hard machining" as compensation
for the previous grinding machining with defined cutting Mixed cutting ceramics - especially type SPK - SH2
edge geometry. This aside is necessary to using the new has fine grains (to 1 mm) and dispersed TiCN. This
cutting materials. It has good usability speed steels with increases the hardness, wear resistance, stability and
coatings in the range of 45 to 50 HRC still possible at productivity of the cutting edge. It applies especially to
low cutting speeds [3], [4]. the fine turning of stable parts with smooth cut and
maintain the highest surface quality and close
dimensional tolerance. CBN - eg. WURBON SPK-

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reported versus SH2 even higher hardness and toughness
quarries. For hard turning is an appropriate species with a
45 ÷ 65% CBN.
The manufacturer offers the CA-EN tipped CBN CA
or smaller monolith of CBN. The answer to the question
of when and where can apply mixed cutting ceramics or
CBN, we can see directly on the practical results. In the
rating test according to VDI - Directive 3324 [7] turned
parts with intermittent cutting-Fig. 1 and Fig. 2.
Cutting parameters: (practical experiment of turning) Fig. 2. Practical example of part interrupted hard turning for properties
-1 of mixed cutting ceramics and CBN comparison [6]
vc = 110 m.min f = 0,15 mm/rev
ap = 0,1 mm dry CBN turning. Another example of technological practice is turning
a longitudinal cut hardened components' „STABILNE
The next example was machining the hole with a TESNENIE“ (Fig. 3) 14100.4 of the material with a
groove for housing a pen. Here in both cases upheld the hardness of 60 to 62 HRC. Workpiece turning is realized
better- CBN WURBON 500th. In contrast, in the smooth on the machine SV RB-18 and later (since 1999) on the
section and added more uniformly comply SH2, thanks machine KUMER-K40. Machined parts were clamp at
to much lower cost per cutting edge compared CBN CA. the hole, fastened to the NC mandrel spindle machine.
The tool holder CTANR 25 x 25 - P16 We used two
The difference in time between machining with CBN
types of cutting discs. The first type was used TNBN
or mixed cutting ceramics is because both operating at
160,408 (60 VOK /Russia/, and a second DBM-SPK -
approximately the same measurement conditions. But Feldmühle /Germany/).
using mixed cutting ceramics can increase the depth of
cut (ap) and thereby reduce the number of shots and that After heat treatment in protective atmosphere and
is the time. This illustration shows the Fig. 2 - cylinder abrasion after clamping both the opening and initially
for cutting wires. made a plunge grinding round, and the difficulties in
achieving the desired roughness of Rt = 1.8 μm
Cutting technology parameters: from practical example: respectively. Ra = 0.4 μm. The work took tk = 3.2 min.
Tool: 1 2 The turning diameter 38.659 ± 0.02 mm to 7.3 mm in
length CC: + Al2O3 TiC from the two cutting parameters
Cutting material: SH2 CBN
were tested to replace the plunge grinding. Technology
Insert: CNGN 120716S TNGN 110305S was used to test wear time exceeded roughness Rt = 1.8
vc [m.min-1] 100 120 μm. It corresponds to the wear plate cutting back VB =
f [mm] 0,08 0,1 0.12 ÷ 0.18 mm, which was identified from the curves
ap [mm] 3,0 1,2 the values Rt = f (time) in the application of different
number of cuts 4 10 cutting speed "vc".
machining time 60% 100%
ts [min] 18 30 To achieve Ra = 0.4 μm feed size was optimized. The
best came shift value f = 0.05 mm/rev. In this feed value,
Workpiece material: X210 CrW12, hardness HRC = depth of cut ap = 0.15 mm and vc = m.min-163 has a
62. shelf-life T = 210 pc components, machining and
mechanical time t = 0.11 min and unit time t k = 0.5 min.
The price of one disc of CC was around 15 Є/pc, the first
Since long-term turning on the machine SV-18 RB
occurred at high speed to the saliency map and the speed
had to be reduced to n = 1120 min-1, therefore, since
1999 turn on the machine KUMER-K40.
When turning by dry heat, there were parts where the
climate dimension is of about 0.02 mm. Today with a
chilling turn as CBN emulsion. Nowadays in the
SAUER-DANFOSS Co., the SpA be done to turn the
average CBN - KD 050 - CA - 160308 or TPEN DCGW
11T304.Cutting parameters for turning on the machine
with PCBN Traub TNS-65-CNC with cold emulsion 5%
are:
n = 1300 ÷ 1500 min-1vc = 157 ÷ 182 m.min-1
f = 0,05 mm/rev vf = 75 ÷ 90 mm.min-1
ap = 0,15 mm ts = 0,11 min tk = 0,50
min T = 26,4 ÷ 27,5 min =
240 ÷ 250 pc, at the VBk = 0,15 mm.
In addition to "hard-grinding turning point" is more
practical and see reciprocal replacement. This is where
Fig. 1. CBN tool life comparison after hard turning process [6]
the builder is required of any partial surface roughness,

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which cannot be achieved by hard turning. It is actually a
replacement of rough grinding by turning when
combined machining to reach the intermediate and
shorter preparation times [2], [5].
Operation: Diameter turning 38, 66-0,02 mm x 7,3 mm
Workpiece clamping: special fixture for hole Ø35,7 H8,
case width 15,6 mm, max. Ø=60,45 mm
Material: 14109.4 (100 Cr6), after hardening to HRC =
60+2 ad after hole grinding for clamping Fig. 3. Machined part “STABILNÉ TESNENIE” from the SAUER
DANFOSS production process after hard turning with cutting
Machine tool: KUMMER K40 –CNC ceramics, or with CBN [7]

Tool holder: SDJCL 2525 M12 The graphical menu of the windows machines CNC
Insert: a) cutting ceramics TNMN 160408, SH1 (SPK programmer defined data of management system for
Feldműhle) or VOK 60 (Russia) fishing cutting tools, cutting conditions, work sliding,
b) PCBN (BN) –DCGW 11T308 – PB050, or taking the shape and dimensions and contours below.
type TPEN 160308 –KD 050 The overall structure of the CNC program, created in the
Manual Guide-i contains the following structure:
Cutting parameters:
n = 1300 ÷1500 min-1 vc = 190 ÷ 200 m./min 1. register the name of the program and insert the
f = 0,05 mm/rev vf = 75 ÷ 90 mm/min required machinery and auxiliary functions,
ap = 0,15 ÷ 0,25 mm 2. define the size and shape of the blank,
Technological wear criterion was exceeded the value of 3. ramp down into the turret tool change point
surface roughness Rt = 1.8 μm, what is recessing 4. onto the turret to the starting point of beginning of the
grinding makes very difficult. cycle machining,
5. determine the parameters of the machine cycle by
Reached results: clinical and graphical menu,
a) without coolant b) with UNIMET 5% coolant 6. built drawings, taking the shape contour including its
T(a) =180÷210 pc VBk = 0,12÷0,18 mm dimensions,
T(b) = 240 ÷250 pc VB k = 0,15 mm 7. output setting point of the tool, tool change, stopping
Ra(a)= 0,3÷0,4 μm (Rtmax(a) =1,8μm) speed, cutting fluid etc.,
Ra(b) = 0,32÷0,38 μm (Rt max (b) = 1,8 μm) 8. for using multiple operating cycles repeat procedure
Turning time: tAS = 0,11 min, tk = 0,5 min 9. simulation of cutting process (see on Fig. 5 and 6).
Grinding time: tk´ = 3,2 min
CNC program, created in the Manual Guide i, can be
3. AUTOMATION PROCESS OF TURNING IN converted to ISO format, which is the extension Fanuc
MANUAL GUIDE-i CNC SYSTEM universal use.

The shape of the individual components for the 3.1 Program features and modes, practical example
automotive industry and subsequently of time and Higher product MANUAL GUIDE-i to work in EDIT
relative complexity of the conversion work and tool paths mode (creating a change in the program), JOG (manual
for CNC program preparation led to the establishment of mode to capture and correction tools, determining the
internal and external graphics support for the creation of work origin cultivated parts) MEM and (graphic
individual programs. Under an external computer simulation and collision in the determination of NC
graphic-promoting wise use of CAD/ CAM systems from program, run = automatic machining mode CNC
the technical documentation, modeling shapes of parts machine). Particularly important is the EDIT mode, it
and final source intermediate to the setting aside of becomes NC program. The new program will create
appropriate technology, options and shape correction using software keys START, and END OF CYCLE. In
tools, manufacturing process simulation of CNC machine the START menu, we define the beginning of the
to use for the appropriate postprocessor to generate NC program (using predefined templates), the shape and
program suitable for CNC machine tool [4]. Another dimensions of the blank. The menu features CYCLE
solution is the installation of internal support system. programming cutting conditions, the selection of
Such a solution as an extension of classical control machining technology and final shape of the components
system called CNC FANUC Manual Guide-i. This utilized by shifting panels and graph icons.
software is an integral part of CNC machine tools. In EDIT mode, also we make various changes and
In practice, we can meet with each of these add-series modifications NC program. In automatic mode, the
systems. The shape and control system FANUC graphic MEM can be created graphically simulated programs,
post is the same in CNC lathes and milling machines. which is beneficial for control. The error in the program,
MANUAL GUIDE-i contains elements of CAD / CAM we created a system alert and alarm stops running
and classical programming. CNC program can be created programs on it that the collision site. The animation is
manually typing each CNC code as in the classical possible to change the size and views on the machining
programming, but many operations consist of structures process as well as chart the way clinical and imaging.
and CAD/CAM programming [6]. JOG In manual mode can be controlled machine tool
using a hand wheel.

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 CNC machine programmer can itself change the size 4. CONCLUSION
of the control feed rates and spindle speeds. CNC lathe
work normally in two axes, namely the horizontal-axis This presented paper describes the methods and
(axis machining of parts) and a vertical wall X-axis various standards of CNC machine tools programming in
perpendicular to the axis, which indicates the average of the manufacturing (hard turning) process.
manufactured parts (see on Fig. 4).
Contribution of the authors solved the problem
If necessary, the cutting grooves on the circumference presents an original solution of the manufacturing
of a rotating head parts or drilling holes on the surface process with the support of FANUC CNC control
and headed out of the central axis of the workpiece, there system. Practical experiments confirm hardened steel
are adjustable CNC lathe with C axis spindle and the new grinding accuracy of compensation hard turning. The
Y-axis perpendicular to the axis X. results presented in this paper can be further exploited in
the process of teaching courses and programming
machines and technical practice for upgrading older
solutions and processes of the main and additional times,
while maintaining the dimensional accuracy of machine
parts. Further research will be based CNC programming
parts with complex shapes see links in the author of the
modern CNC machines using modern types of cutting
materials for machining.

5. ACKNOWLEDGEMENTS

Fig. 4. Hard turning of part made of C120U steel on AERO TURN 350 Our presented scientific paper was to connection
BT CNC Machine tool [7] between the theory of drilling and of industrial practice.
The practical measurement of specimen part was
conducted in cooperation with the VSM – The School of
Management, along with industrial companies of the
region of Trencin (e.g. MASH Integration Co. Trencin).

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