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. 2025 Feb 20;18(5):921.
doi: 10.3390/ma18050921.

Experimental Insights into Free Orthogonal Cutting of Stellite

Miroslav Gombár  1 , Marta Harničárová  2   3 , Jan Valíček  2   3 , Milena Kušnerová  3 , Hakan Tozan  4 , Rastislav Mikuš  5
Affiliations

Experimental Insights into Free Orthogonal Cutting of Stellite

Miroslav Gombár et al. Materials (Basel). .

Abstract

The effectiveness of a machining process can be determined by analysing the quality of the generated surface and the rate of tool wear. Stellite is highly challenging to machine, which is why it is primarily processed through grinding methods. This study concentrates on the impact of cutting parameters and tool wear (VBb, KBb) on the created surface roughness surface (Rt, Ra, Rz) during the orthogonal cutting of Stellite 6, which is overlaid on a steel surface, C45, prepared by means of HP/HVOF (JP-5000). The results indicate that the dominant influence on the change in the total roughness profile height value (Rt) is the mutual interaction of cutting speed and depth of cut at 16% (p < 0.000). The greatest impact on the change in the mean arithmetic deviation of the roughness profile (Ra) value is the interaction of cutting speed, tool front angle, and depth of cut with a 15% share (p < 0.000), as well as on the change in the Rz value (15%) and tool wear VBb (25%). This investigation lays the groundwork for potentially substituting the processing of flat surfaces with hardened layers created by thermal spraying (such as Stellite 6) with grinding or methods that offer greater efficiency from both economic and technological perspectives.

Keywords: HP/HVOF; Stellite 6; orthogonal cutting; surface roughness; wear.

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Conflict of interest statement

The authors declare no conflicts of interest.

Figures

Figure 1
Figure 1
Microstructure of the Stellite 6 machined material: (a) interface between the base material and the coating; (b) gap between the coating deposits; (c,d) ferritic and pearlitic microstructures of C45.
Figure 2
Figure 2
Chemical composition of the (a) coating; (b) the thickness of Stellite 6 coating.
Figure 3
Figure 3
Microhardness values (HV 0.1) on Stellite 6: (a) variation in HV 0.1 as a function of distance from the surface of the coating; (b) microhardness measurement record.
Figure 4
Figure 4
Implementation of experimental verification: (a) a horizontal trimming machine, (b) a more detailed view of the machine’s workspace.
Figure 5
Figure 5
Machining tool: (a) tools for different variations of face angles, (b) technical drawing of the tool for γ = 0°.
Figure 6
Figure 6
Effect of the cutting speed (vc) and the tool face angle (γ) on the change in the value of the total roughness profile height Rt: (a) ap = 0.10 mm; (b) ap= 0.30 mm.
Figure 7
Figure 7
Effect of the cutting speed (vc) and the tool face angle (γ) on the change in the value of the mean arithmetic deviation of the roughness profile Ra: (a) ap = 0.10 mm; (b) ap = 0.30 mm.
Figure 8
Figure 8
Effect of cutting speed (vc) and face angle (γ) on the change in the value of the largest profile height Rz: (a) ap = 0.10 mm; (b) ap = 0.30 mm.
Figure 9
Figure 9
Roughness profile record for the cutting speed vc = 33.0 m·min−1: (a) γ = −7°, ap = 0.1 mm; (b) γ = 0°, ap = 0.1 mm; (c) γ = +7°, ap = 0.1 mm; (d) γ = −7°, ap = 0.3 mm; (e) γ = 0°, ap = 0.1 mm; (f) γ = +7°, ap = 0.1 mm.
Figure 10
Figure 10
Roughness profile record for the cutting speed vc = 92.0 m·min−1: (a) γ = −7°, ap = 0.1 mm; (b) γ = 0°, ap = 0.1 mm; (c) γ = +7°, ap = 0.1 mm; (d) γ = −7°, ap = 0.3 mm; (e) γ = 0°, ap = 0.3 mm; (f) γ = +7°, ap = 0.3 mm.
Figure 11
Figure 11
Effect of the cutting speed (vc) and face angle (γ) on the variation in the tool back wear area (VBb): (a) ap = 0.10 mm; (b) ap = 0.30 mm.
Figure 12
Figure 12
Wear pattern of the back surface of the VB toolb: (a–l): a series of 12 microscopic images with different machining parameters (marked in the image caption).
Figure 13
Figure 13
Effect of the cutting speed (vc) and the face angle (γ) on the change in the tool face wear area (KBb) (a) ap = 0.10 mm, (b) ap = 0.30 mm.
Figure 14
Figure 14
Wear pattern of the KBb tool face: (a–l): a series of 12 microscopic images with different machining parameters (marked in the image caption).
Figure 15
Figure 15
Detailed view of the machining process shape of the emerging chip at cutting speeds of vc = 33.0 m·min−1 and vc = 47.0 m·min−1 and the depth of cut ap = 0.10 mm.
Figure 16
Figure 16
Detailed view of the machining process shape of the emerging chip at cutting speeds of vc = 65.5 m·min−1 and vc = 92.0 m·min−1 and the depth of cut ap = 0.10 mm.
Figure 17
Figure 17
Model performance metrics.
Figure 18
Figure 18
Comparison graph of the importance of properties between the Ra, Rq, Rz models.
See this image and copyright information in PMC

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