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<p>Form turning inserts contribute significantly to cost reduction by consolidating the functions of multiple tools and minimizing tool change durations, thereby enhancing overall machining efficiency. Observations during the turning of bearing outer rings indicate that variations in the insert’s rake angle led to dimensional inconsistencies, necessitating the optimization of this angle for each specific bearing design. In the industry, the most suitable geometry for bearing ring turning is usually determined by the trial-and-error method, which causes disadvantages such as increased time and cost. To address these limitations, a three-phase investigation was carried out focusing on a cermet insert designed for bearing outer ring applications, encompassing FEM-based cutting simulations, precision manufacturing, and experimental performance evaluations. Firstly, the limits of the γ value of the insert were determined by FEM-based turning simulations performed before its production. Then, a series of grinding and honing operations were applied to produce the form inserts. Performance tests were conducted using three rake angles, three honing durations, and different cermet grades. The factors investigated in the cutting simulations (cutting forces, tool stresses and tool-chip interface temperature) showed that rake angles in the range of 2°–6° can be applied for the insert with optimum characteristics. Performance tests were performed until deviations occurred in the bearing outer ring dimensions and the number of processed parts was taken as the basis for the life of the form tool. Analysis of variance (ANOVA) and Pareto evaluation identified rake angle as the most influential parameter (61.05%), followed by cermet grade (16.33%) and honing duration (14.24%). The best performance was achieved with TN90 quality insert, a 4° rake angle, and 7 min honing time, processing a maximum of 2456 bearing rings within the desired tolerances. Accordingly, it was shown that FEM-assisted form tool design and production can be done with the desired efficiency for an industrially produced product.</p>

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Comprehensive analysis of FEM assisted cermet insert design and tool performance for turning bearing rings

  • 期刊论文

  • 发表日期：

    2025年8月1日

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  • MUSTAFA GÜNAY,
  • MUHAMMED ÖMER KAYKI,
  • AHMET FATİH YILMAZ

摘要

Form turning inserts contribute significantly to cost reduction by consolidating the functions of multiple tools and minimizing tool change durations, thereby enhancing overall machining efficiency. Observations during the turning of bearing outer rings indicate that variations in the insert’s rake angle led to dimensional inconsistencies, necessitating the optimization of this angle for each specific bearing design. In the industry, the most suitable geometry for bearing ring turning is usually determined by the trial-and-error method, which causes disadvantages such as increased time and cost. To address these limitations, a three-phase investigation was carried out focusing on a cermet insert designed for bearing outer ring applications, encompassing FEM-based cutting simulations, precision manufacturing, and experimental performance evaluations. Firstly, the limits of the γ value of the insert were determined by FEM-based turning simulations performed before its production. Then, a series of grinding and honing operations were applied to produce the form inserts. Performance tests were conducted using three rake angles, three honing durations, and different cermet grades. The factors investigated in the cutting simulations (cutting forces, tool stresses and tool-chip interface temperature) showed that rake angles in the range of 2°–6° can be applied for the insert with optimum characteristics. Performance tests were performed until deviations occurred in the bearing outer ring dimensions and the number of processed parts was taken as the basis for the life of the form tool. Analysis of variance (ANOVA) and Pareto evaluation identified rake angle as the most influential parameter (61.05%), followed by cermet grade (16.33%) and honing duration (14.24%). The best performance was achieved with TN90 quality insert, a 4° rake angle, and 7 min honing time, processing a maximum of 2456 bearing rings within the desired tolerances. Accordingly, it was shown that FEM-assisted form tool design and production can be done with the desired efficiency for an industrially produced product.