Control concept for the regulation of the surface layer properties using consecutive cuts in cryogenic hard turning of AISI 52100

Abstract In this study, a control concept for the simultaneous adjustment of the workpiece residual stresses and the surface roughness when cryogenic hard turning AISI 52100 is presented. The turning process is comprised by two consecutive cuts in which the process parameters vary, focusing on roughing and finishing; i.e. first a high, then a low depth of cut. On the first cut, the surface residual stress is adjusted via the cutting speed. On the second cut, the surface roughness is minimized by adjusting the feed rate while maintaining high compressive residual stresses. The surface residual stresses are determined by XRD and hole drilling measurements. For the estimation of the residual stresses the passive force is used. Based on these results, a control concept is presented which makes several assumptions that are partly validated by experiments.