1、AN AMERICAN NATIONAL STANDARD Tool Life Testing With Single-Point I urning Tools ANSIIASME B94.55M - 1985 SPONSORED AND PUBLISHED BY THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS United Engineering Center 345 East 47th Street New York, N. Y. 1001 7 Date of Issuance: April 15, 1986 This Standard will
2、be revised when the Society approves the issuance of a new edition. There will be no addenda or written interpretations of the requirements of this Standard issued to this Edition. This code or standard was developed under procedures accredited as meeting the criteria for American National Standards
3、. The Consensus Committee that approved the code or standard was balanced to assure that individuals from competent and concerned interests have had an opportunity to participate. The proposed code or standard was made available for public review and comment which provides an opportunity for additio
4、nal public input from industry, academia, regulatory agencies, and the public-at-large. ASME does not “approve,“ “rate,“ or “endorse“ any item, construction, proprietary device, or activity. ASME does not take any position with respect to the validity of any patent rights asserted in connection with
5、 any items mentioned in this document, and does not undertake to insure anyone utilizing a standard against liability for infringement of any applicable Letters Patent, nor assume any such liability. Users of a code or standard are expressly advised that determination of the validity of any such pat
6、ent rights, and the risk of infringement of such rights, is entirely their own responsibility. Participation by federal agency representative(s) or person(s) affiliated with industry is not to be interpreted as government or industry endorsement of this code or standard. ASME accepts responsibility
7、for only those interpretations issued in accordance with governing ASME procedures and policies which preclude the issuance of interpretations by individual volunteers. No part of this document may be reproduced in any form, in an electronic retrieval system or otherwise, without the prior written p
8、ermission of the publisher. Copyright 0 1986 by THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS All Rights Reserved Printed in U.S.A. FOREWORD (This Foreword is not part of ANWASME B94.55M-1985.) This Standard is a slightly modified version of IS0 3685-1977, Tool Life Testing With Single-Point Turning
9、Tools. Only several small changes have been made, such as replacing referenced IS0 materials specifications with ASTM and ANSI specifications. It was felt that U.S. users of the Standard would be more familiar with the ASTM and ANSI specifications and have easier access to them. Following approval b
10、y the B94 Standards Committee and ASME, this Standard was submitted to ANSI and approved as an American National Standard on November 27, 1985. 111 . Intentionally left blank ASME STANDARDS COMMITTEE B94 Standardization of Cutting Tools, Holders, Drivers, and Bushings (The following is the roster of
11、 the Committee at the time of the approval of the Standard.) OFFICERS E.J. Czopor, Chairman W.R. Daisak, Secretary COMMITTEE PERSONNEL AMERICAN SOCIETY OF MECHANICAL ENGINEERS, THE M.E. Merchant, Metcut Research Associates, Inc., Cincinnati, Ohio G.F. Wilson, Alternate, General Electric Co., Worthin
12、gton, Ohio CUTTING TOOL MANUFACTURERS OF AMERICA E.J. Czopor, Falcon Tool Co., Warren, Michigan C.W. Jatho, Alternate, Cutting Tool Manufacturers of America, Birmingham, Michigan GENERAL SERVICES ADMINISTRATION W.R. Wacker, General Services Administration, Washington, DC HACK AND BAND SAW MANUFACTUR
13、ERS ASSOCIATION OF AMERICA R. Schrade, Clemson Brothers, Inc., Middletown, New York C.M. Stockinger, Alternate, Hack and Band Saw Manufacturers Association, Cleveland, Ohio METAL CUTTING TOOL INSTITUTE W.A. Wagner, Cleveland Twist Drill Co., Cleveland, Ohio J.G. Thirnrnig, Alternate, Metal Cutting T
14、ool Institute, Cleveland, Ohio NATIONAL MACHINE TOOL BUILDERS ASSOCIATION J.J. Robinson. Valeron Corp Troy, Michigan A.M. Bratkovich, Alternate, National Machine Tool Builders Association, McLean, Virginia SOCIETY OF MANUFACTURING ENGINEERS G.L. Spencer, Ford Motor Co., Detroit, Michigan UNITED STAT
15、ES DEPARTMENT OF THE ARMY D.L. York, Liaison, Material Readiness Command, Rock Island, Illinois INDIVIDUAL MEMBERS A. Ashburn, American Machinist, New York, New York H. Cooper, Water Technology, Inc., Troy, Michigan R.T. Koblesky, lngersoll Cutting Tool Co., Rockford, Illinois J.A. Lang, Dayton Prog
16、ress Corp., Dayton, Ohio L. Storrer, Mohawk Tools, Inc., Montpelier, Ohio V PERSONNEL OF TECHNICAL COMMITTEE 4 - LIFE TESTING WITH SINGLE-POINT TOOLS M.E. Merchant, Chairman, Metcut Research Associates, Inc., Cincinnati, Ohio R.M. Byme, Trade Association Management, Inc., Tarrytown, New York D.D. Ja
17、ckson, Valeron Corp., Warren, Michigan J. Johnston, General Electric Co., Warren, Michigan J.F. Kahles, Metcut Research Associates, Cincinnati, Ohio J.D. Knox, Vermont American Corp., Louisville, Kentucky vi CONTENTS Foreword Standards Committee Roster 0 1 2 3 4 5 6 7 8 9 10 Introduction . Reference
18、s . Workpiece . Tool Cutting Fluid . Cutting Conditions Tool Life Criteria and Tool Wear Measurements . Equipment . Tool Life Test Procedure . Recording and Reporting Results Scope and Field of Application Figures 1 ToolAngles 2 Details of Rounded Corner 3 Tolerances on Squareness of Insert and Tool
19、holder Location 4 Insert Overhang and Chipbreaker . 5 Regrinding Tool After Testing 6 Limits of Cutting Conditions . 7 Broken v.TCurve. Combined Flank and Crater Wear 8 Some Types of Wear on Turning Tools . 9 Development of Flank Wear for Different Cutting Speeds . 10 Development of Crater Depth for
20、 Different Cutting Speeds 11 v-TCurvefor VBB = 0.3 mm . 12 v-TCurve for KT = 0.18 mm . 13 Number of Workpieces Produced as a Function of Spindle Speed . Tables 1 Standard Tool Angles. deg 2 Standard Cutting Conditions . 3 Limits of Other Cutting Conditions 4 Geometric Series of Preferred Numbers for
21、 Cutting Speeds (m/min) Appendices A General Information B Grinding of High-speed Steel . C Tool Wear and Tool Life Criteria D Datasheets . 111 V 1 1 1 2 3 7 7 10 12 12 12 4 5 6 6 7 9 9 11 13 13 14 14 14 17 19 23 27 vii E Preliminary Tool Life Test . 3 1 F Evaluation of Tool Life Data . 33 G Chip Fo
22、rms 49 Figures 14 21 15 21 16 33 17 Lines Fitted “By Eye” . 39 18 Lines With Confidence Interval Fitted by Calculation . 40 Tables 5 Grinding Recommendations 20 7 Computation Schedule for Assessment of Dispersion and Significance . 42 8 Computation Schedule for Calculation of Confidence Intervals 43
23、 11 Example . 46 12 ?-Distribution for 95% Confidence Level . 47 6 Computation Schedule for Calculation of Regression Line . y = a + k(x . X) 41 9 Example . 44 10 Example . 45 viii ANSI/ASME B94.55M-1985 AN AMERICAN NATIONAL STANDARD AN AMERICAN NATIONAL STANDARD TOOL LIFE TESTING WITH SINGLE-POINT
24、TURNING TOOLS 0 INTRODUCTION Tool life testing has been carried out for at least 75 years, in tremendously increasing volume, but under a variety of cutting conditions and methods having little in common with each other. Thus, a need exists for standardization of tool life testing conditions appli-
25、cable not only in laboratories but also in production plants. The test conditions have been specified in such a way that the different factors which affect the results of tool life testing will all be under a reasonable and practical degree of control. This Standard has been so framed that it can be
26、 directly applied to industrial testing and in research. For research purposes, however, this Standard should be considered to be only a minimum set of conditions, since greater attention may have to be given to the fac- tors which affect the variability of the tool life values. Although the test pa
27、rameters are standardized, any one or more of them may become variables in any given test when they are the quantities being examined. The limits of the specification of the reference mate- rials are left rather wide for practical reasons. It should be understood that results may vary from batch to
28、batch. If reproducibility is essential, special requirements should be discussed with the supplier of the work material. The specifications for test conditions given in this Standard are primarily suited to testing on steel and cast iron work materials. However, with suitable modification they can a
29、lso be made applicable to test- ing on other materials. The specifications for test conditions are also mainly applicable to tool life testing in which the tool wears at a conventional rate and in a conventional manner. However, it is evident that they may also be applied to some types of accelerate
30、d tool life testing. If, for some reason, it is necessary to deviate from the specifications given in this Standard, this shall be reported in detail. NOTE: This Standard is not an acceptable test and it is not advis- able to use it as such. 1 SCOPE AND FIELD OF APPLICATION This Standard establishes
31、 specifications for the fol- lowing factors of tool life testing with single-point turning tools: workpiece, tool, cutting fluid, cutting conditions, tool wear and tool life, equipment, test procedures, recording and reporting and presentation of results. Further general information is given in Appe
32、ndix A. 2 REFERENCES The latest issues of the following documents form a part of this Standard to the extent specified herein. American Society for Testing and Materials ASTM A 159-83, Standard Specification for Automo- ASTM A 576-81, Standard Specification for Steel Bars, Carbon, Hot-Wrought, Speci
33、al Quality (Grade G 10450) ASTM E 18-79, Standard Test Methods for Rockwell Hardness and Rockwell Superficial Hardness of Metallic Materials ASTM E 92-82, Standard Test Method for Vickers Hardness of Metallic Materials ASTM E 112-82, Standard Methods for Determining Average Grain Size tive Gray Iron
34、 Castings (Grade G 3000) 1 ANSVASME B94.55M-1985 AN AMERICAN NATIONAL STANDARD TOOL LIFE TESTING WITH SINGLE-POINT TURNING TOOLS American National Standards Source Nitrogen Content, (70 ANSI B46.1-1978, Surface Texture ANSI B74.3-1982, Markings for Identifying Grinding ANSI B94.4-1976, Identificatio
35、n System for Index- ANSI B94.50-1975, Basic Nomenclature and Defini- Wheels and Other Bonded Abrasives able Inserts for Cutting Tools tions for Single-Point Cutting Tools 3 WORKPIECE 3.1 Work Material In all cutting tests in which the work material is not itself the test variable or is not itself an
36、 important pa- rameter, the investigation shall be conducted on the appropriate one of the reference materials indicated in paras. 3.1.1, 3.1.2, and 3.1.3. In the exceptions quoted, however, it is desirable to conduct tests on a reference material for comparative purposes. The provision of a well-de
37、fined reference work material shall be discussed with the manufacturer. 3.1.1 Steel. The steel reference material shall be a hot-rolled medium carbon steel corresponding nomi- nally to ASTM 1045 (A 576-81) but of the following controlled composition. 0.42 0.15 0.50 0.02 0.50 0.40 0.80 0.035 The pres
38、ence of the following elements in excess of the maximum values given below shall disqualify the steel as a reference test material. Ni = 0.20% Cr = 0.15% MO = 0.05% v = 0.02% cu = 0.20% The steel shall be deoxidized with aluminum and the minimum aluminum content shall be 0.01 070. Special deoxidants
39、 shall not be used. The nitrogen content, being to some extent depen- dent on the steelmaking source, shall be as follows: Open hearth or oxygen 0.003 to 0.006 converters Arc, single slag 0.004 to 0.008 It will be necessary to analyze the steel for nitrogen. The steel should be purchased to ASTM A 5
40、76-81 specifications, but special quality bars meeting the above criteria should be specified. The limits of the elements and deoxidation practice shall be discussed with the steelmaker and analyses of C, Si, Mn, Ni, Cr, Mo, P, S, V, Cu, Al, and N requested at the time of the order. The minimum init
41、ial test bar diameter shall be 100 mm, but the actual initial diameter shall be reported. The test bars, after being cut to length, shall be nor- malized to a Brinell hardness of 180 to 200 HB. The actual hardness shall be reported. 3.1.2 Cast Iron. The cast iron reference material shall correspond
42、nominally to ASTM A 48, Class 25 (ASTM A 159-81), with a Brinell hardness of 200 to 220 HB . If available, the following material shall be used. The microstructure throughout the entire volume of each cast iron test bar shall consist essentially of a matrix of 100% pearlite with flake graphite withi
43、n the following specification: Pearlite 100% Free iron carbide 0 070 Free ferrite 5% max. Steadite (iron-iron phosphide eutectic) 5% max. Graphite flake graphite only 3.1.3 Other Work Materials. Where the work ma- terial is not one of the reference materials, if possible, the grade, chemical composi
44、tion, physical properties, microstructure, and complete details of the processing route of the work material (for example, hot-rolled, forged, cast, or cold drawn) and any heat treatment shall be reported. 3.2 Standard Conditions for the Workpiece All mill scale or casting skin shall be removed by c
45、leanup cuts before testing, except when the effect of the scale is being tested. 2 TOOL LIFE TESTING WITH SINGLE-POINTTURNING TOOLS ANWASME B94.55M-1985 AN AMERICAN NATIONAL STANDARD The metal forming the surface of the shoulder, i.e., “the transient surface,“ and any other burnished or abnormally w
46、ork-hardened surface on the workpiece which can come in contact with the test tool shall be removed with a sharp cleanup tool prior to testing in order to reduce as much as possible the residual sub- surface deformations due to the previous test. How- ever, this does not include removal of the norma
47、lly work-hardened surface on the test bar produced by the previous passes of the tool. The length/diameter ratio of the workpiece shall be not more than the minimum ratio at which chatter occurs. The test shall be stopped when chatter occurs. A length/diameter ratio greater than 10 is not recommende
48、d. The hardness of the work material shall be deter- mined over the complete cross section of one end of each test bar. The cutting test shall be conducted only on the bar in the range of diameters where the hardness lies within the limits given by the original hardness specification. Quantitative m
49、etallography (as regards microstruc- ture, grain size, inclusion count, etc.) of the work ma- terial is recommended but when this is not practical, photomicrographs shall be included in the report. The magnification shall be in the range 100 to 500. In machining tests carried out on production com- ponents, the fixing devices normally employed in the process shall be utilized. The chuck and the spindle shall be stable and well balanced. When fixing the workpiece between a chuck or a face plate and a center, special care shall be taken to prevent any bending loads on the workpiece. A center ho
