Tool wear effects on white and dark layer formation in hard turning of AISI 52100 steel

In the present investigation a series of orthogonal hard turning tests were conducted to study the effects of tool wear and cutting parameters (cutting speed and feed rate), on white and dark layer formation in hardened AISI 52100 bearing steel, using PCBN inserts. Experimental results were presented including quantification of tool wear and microstructure analysis of the machined surfaces. The experimental results were compared with a newly developed finite elements (FE) model that enables to capture the effect of cutting conditions and tool wear on the microstructural changes occurring at the machined surface. The results showed that cutting regime parameters and, especially, tool wear affect noticeably white and dark layers formation.

► Analysis of the influence of tool wear and process parameters on white and dark layers formation. ► Tool life tests using PCBN tool and cutting AISI 52100 Steel. ► 2D and 3D FEM simulations able to provide the thickness of white and dark layer formation are here reported. ► Comparison between experimental and simulated results are discussed.