ISSN 1068-798X, Russian Engineering Research, 2018, Vol. 38, No. 2, pp. 126–129. © Allerton Press, Inc., 2018.
Original Russian Text © V.N. Puchkin, A.A. Ryzhkin, V.A. Kokhanovskii, T.V. Kashcheeva, I.D. Storozhenko, 2017, published in STIN, 2017, No. 8, pp. 19–24.
Improved Smoothing by a Tool with Ceramic Inserts
V. N. Puchkin
, A. A. Ryzhkin
, V. A. Kokhanovskii
T. V. Kashcheeva
, and I. D. Storozhenko
Armavir Mechanical and Technological Institute, Kuban State Technical University, Armavir, Russia
Don State Technical University, Rostov-on-Don, Russia
Kuban State Technical University, Krasnodar, Russia
Abstract—A dynamic system is analyzed by the simulation of two subsystems (for the part and the tool) that
interact through the dynamic link formed by the machining process. This link corresponds to the smoothing
forces, which may be expressed in terms of the state of the dynamic system. The dynamic stability and behav-
ior of the system are expressed in terms of displacements from equilibrium.
Keywords: smoothing, cutter, cutting ceramics, plastic deformation, process dynamics, surface-layer for-
IN SMOOTHING BY A TOOL
WITH A CERAMIC INSERT
In manufacturing, it is important to improve the
reliability and durability of the machine parts that
determine overall performance. That implies improv-
ing the quality of the surface layer.
In surface plastic deformation (in particular,
smoothing) by a tool with inserts made of cutting
ceramic, the surface layer is formed as a result of com-
plex interrelated phenomena that occur in the defor-
mation region and its surroundings. These phenom-
ena largely eliminate the structure changes in the
workpiece’s surface layer due to prior cutting pro-
cesses (especially in grinding). The surface layer is
strengthened, and compressive residual stress is
formed there. That increases the life and performance
of the parts produced. In finishing by surface plastic
deformation, the roughness of the surface layer is
modified [1–3]. Surface plastic deformation offers the
following benefits over polishing and lapping .
(1) Minimal surface roughness of parts made from
steels that are stable at high temperatures and hard to
≤ 0.05 μm).
(2) Severalfold decrease in surface roughness per
pass of a tool with a VOK-60 ceramic insert.
(3) Creation of surface microprojections with a
large supporting area.
(4) Consistent increase (by 25–55%) in wear resis-
tance, fatigue strength, and contact strength of the
(5) No tainting of the machined surface with parti-
cles from the grinding wheels and abrasive paste. That
reduces the auxiliary time required.
In appropriate machining conditions, these bene-
fits improve the performance by a factor of 1.5–2.5. In
smoothing by a tool with a VOK-60 ceramic insert, the
indenter slips over the workpiece surface. In so doing,
it creates a channel dividing the deformed surface into
sections. This deformation of the metal ahead of and
on either side of the indenter forms ridges of plastically
deformed metal. That is associated with a deformation
wave . The surface deformation is shown in Fig. 1.
We now consider the deformation of the work-
piece’s surface layer in the direction of the shaping
motion (Fig. 1a). The indenter (cutter) 2 is introduced
Fig. 1. Deformation of surface layer (a) and surface forma-
tion (b) in smoothing by a cutter with a VOK-60 ceramic
insert . The dashed line shows the position of the cutter
in the prior workpiece rotation. Notation as in the text.