Method to assess machinability of engineering steels using coated carbide tools

Abstract: In this master thesis, performed at Ovako Group R&D (Hofors) a new machining test method for ranking heats of calcium-treated steels, M-Steels, has been proposed.  A total of six different heats of 42CrMo4-M steel in the quenched-and-tempered (Q+T) condition were tested. The proposed method uses dry turning with coated cemented carbide tools at a cutting speed of 225 m/min, 2 mm depth of cut, and a feed rate of 0.35 rev/min. The machining test is tuned so that M-Steels within medium-sized bar diameters and a small hardness interval can be differentiated by monitoring the flank wear progression of the cutting tool. This method is easily taught to a CNC-operator, it mimics real workshop conditions and can be repeated with relative robustness and ease of execution. It is possible to get a ranking where both the M-Steel treatment and hardness are included.  The major differentiator of tool wear performance was found to be a combination of wear of the outermost Al2O3 coating and the build-up and renewal of protective slag deposits on the tool rake. The rake face wear was found similar between the M-Steels samples, so it is thought that the effect of the slag deposits, as thermal barriers, affect the plastic deformation and wear of the flank face. Given the slag deposits sub-micron thickness, this indirect method of recording the flank wear is highly recommended to showcase the positive effects of the M-Steel in machining The inclusion content was evaluated according to ASTM E45 and with a scanning electron microscope (SEM) automated inclusion assessment. The link between the machinability performance of the M-Steels and their inclusion characteristics could not be clarified in this work.  Teknisk-naturvetenskapliga fakulteten