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. 2019 Aug 10;12(16):2551.
doi: 10.3390/ma12162551.

Investigation of Surface Roughness and Predictive Modelling of Machining Stellite 6

Jan Valíček  1 , Jan Řehoř  2 , Marta Harničárová  2 , Miroslav Gombár  2 , Milena Kušnerová  2 , Jaroslava Fulemová  2 , Alena Vagaská  2
Affiliations

Investigation of Surface Roughness and Predictive Modelling of Machining Stellite 6

Jan Valíček et al. Materials (Basel). .

Abstract

The aim of the paper was to examine the influence of cutting conditions on the roughness of surfaces machined by longitudinal turning, namely of surfaces coated with Stellite 6 prepared by high-velocity oxygen fuel (HVOF) technology and applied onto a standard structural steel substrate. From the results of measurements of the cutting parameters, a prediction model of the roughness parameters was created using mathematical and statistical methods. Based on a more detailed analysis and data comparison, a new method for prediction of parameters of longitudinal turning technology was obtained. The main aim of the paper was to identify the mutual discrete relationships between the substrate roughness and the machining parameters. These were the feed rate vc (m·min-1), in the case of turning and milling, and the feed rate f (mm·rev-1) and the depth of cut ap (mm). The paper compared and verified two approaches of this method, namely the mathematical statistical approach, the analytical approach and measured dates. From the evaluated and interpreted results, new equations were formulated, enabling prediction of the material parameters of the workpiece, the technological parameters and the parameters of surface quality.

Keywords: Stellite 6; longitudinal turning; prediction of topographic parameters; surface roughness.

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Conflict of interest statement

The authors declare no conflict of interest.

Figures

Figure 1
Figure 1
The nominal value of hardness of Stellite 6 spray in hot conditions.
Figure 2
Figure 2
The scanning electron microscope (SEM) microstructure of Stellite 6 (Co-Cr-W alloy)) High pressure (HP)/High velocity oxy-fuel sprayed coating (HVOF) sprayed coating: (a) overview; (b) detail.
Figure 3
Figure 3
Diagram of Stellite 6 machining.
Figure 4
Figure 4
Measurement of surface roughness (real surface).
Figure 5
Figure 5
Prediction of the dependence of the parameter Ra on feed rate f, cutting speed vc and depth of the cut ap.
Figure 6
Figure 6
Dependence of change of the value Ra on the change of cutting conditions: (a) ap = 0.1 mm, (b) ap = 0.15 mm, (c) vc = 200 m·min−1, (d) f = 0.6 mm·rev−1.
Figure 7
Figure 7
Dependences (vco, apo, fo) = f (Emat) for Stellite.
Figure 8
Figure 8
Comparison of (RaM, RaA, Ra) = f(vc) according to values in the columns 7, 8 and 9 in Table 8; RaM measurement data, RaA according to Equation (21), above, and Ra according to Equation (2).
Figure 9
Figure 9
Comparison of (ap, apc) = f (vc) according to values in columns 3 and 12 in Table 1; ap chosen, apc calculated for control according to Equation (23), below.
Figure 10
Figure 10
The effect of blunting the tool edge rt on the surface roughness Ra = f (f).
Figure 11
Figure 11
Comparison of (Ravp, Ravc) = f (vc).
Figure 12
Figure 12
Porosity (npX) = f (Δh) for Stellite.
Figure 13
Figure 13
Porosity (npX) = f (Δh) for WC–Co.
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