• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.20 no.4
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• pp.419-426
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• 2011

In this study, an experimental and theoretical program were carried out to determine the cutting forces and chip formation at different cutting speeds using a 0.4mm nose radius ceramic insert and -7 rake angle for non heat-treated AISI 4140 (27HRc) and heat-treated AISI 4140 (45 HRc) steel. The results obtained were compared to show the hardness differences between the materials. The secondary deformation zone thicknesses when comparing the two materials show different physical structure but similar size. These results were also discussed in light of the heat treatment and the effects it had on the machining characteristics of the material. In addition, the Oxley Machining Theory was used to predict the cutting forces for these materials and a comparison made. The predicted cutting performances were verified experimentally and showed good agreement with experimental data.

• Proceedings of the KWS Conference
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• 2003.11a
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• pp.268-270
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• 2003

No Abstract, See Full Text

• International Journal of Precision Engineering and Manufacturing
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• v.6 no.4
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• pp.55-59
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• 2005

This paper presents a feasibility study whether Shida's constitutive equation being widely used for plain carbon steel in steel manufacturing industry can be extended to alloy steels with a due carbon equivalent model. T,he constitutive relation of the alloy steels (SAE9254, AISI52100 and AISI4140) is measured using hot deformation simulator (GLEEBLE 3500C) at high temperatures ($800^{\circ}C{\~}1000^{\circ}C$) within strain rates of $0.05{\~}40\;s^{-1}$. It has been found the predicted flow stress behavior (constitutive relation) of AISI52100 steel is in agreement with the measured one. On the other hand, the measured flow stress behavior of SAE9254 and AISI4140 steel partly concords with the predicted one when material experiences relatively high strain rate ($10{\~}40\;s^{-1}$) deformation at low temperature ($800^{\circ}C$). It can be deduced that, for AISI52100 steel, Shida's equation with the carbon equivalent model can be applicable directly to the roughing and intermediate finishing stand in hot rolling process for calculating the roll force and torque.

• Tribology and Lubricants
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• v.32 no.5
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• pp.160-165
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• 2016

AISI 4140 steel is widely used in various mechanical components owing to its superior mechanical properties. Surface hardening techniques are often used to further improve the properties, particularly for applications with moving components. The aim of this research is to understand the effect of heat treatment process on surface properties and tribological characteristics of AISI 4140 steel. In this work, we prepare two different AISI 4140 steel specimens- one cooled by air and one by oil- and determine surface properties such as surface topography and roughness using a confocal microscope. We also observe the cross-sections of the specimens using a scanning electron microscope to understand the difference in the material structure. In addition, we assess the hardness with respect to the distance from the surface using a micro-Vickers hardness tester. After characterizing the surfaces of the specimens, we investigate the wear characteristics of the specimens under hydrodynamic lubrication. The results show the presence of grooves on the surface of the oil-cooled specimens. It is likely that such grooves are formed during the cooling process using the oil. However, we observe no other significant differences in the surface properties of the specimens. The wear test results show the occurrence of severe wear on the oil-cooled specimens, which may be due to the groove formed on the surface. The results of this work may be helpful to improve surface properties using surface hardening techniques from a tribological perspective.

• Journal of the Korean Society for Precision Engineering
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• v.31 no.9
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• pp.799-804
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• 2014

Hard turning is a machining process for hardened materials with high surface quality so that grinding process can be eliminated. Therefore, the hard turning is capable of reducing machining time and improving productivity. In this study, hardened AISI4140 (high-carbon chromium steel) that has excellent yield strength, toughness and wear resistance was finish turned using CBN tools. Wear characteristics of CBN tool was analyzed in dry and MQL mixed with nano-particle (Nano-MQL). The dominant fracture mechanism of CBN tool is diffusion and dissolution wear on the rake surface resulting in thinner cutting edge. Abrasive wear by hard inclusion in AISI4140 was dominant on the flank surface. Nano-MQL reduced tool wear comparing with the dry machining but chip evacuation should be considered. A cryogenically treated tool showed promising result in tool wear.

• Proceedings of the KWS Conference
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• 2004.05a
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• pp.45-47
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• 2004

We have investigated the microstructures and the mechanical properties of TiA1/Cerameti1721 (Ag-Cu-Ti insert metal)/AISI4140 joints at 800$^{\circ}C$ for 60 to 300s using induction brazing method. Two continuous reaction layers of AICuTi and AICu$_2$Ti were formed at the interface between the braze and TiAl, whose thickness increased with the brazing time. The braze consisted of Ag-rich, Ti-rich, CuTi and CuTi$_2$ phases. The maximum tensile strength achieved 296MPa, which was 71% of that of TiAl base metal, for the specimen bonded at 800$^{\circ}C$. Further increase of the brazing temperature and time resulted in constant deterioration of its bonding strength due to large amount of brittle IMC.

• Structural Engineering and Mechanics
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• v.84 no.1
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• pp.17-33
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• 2022

An experimental study is carried out to investigate the performance of the cutting tool regarding the insert wear, surface roughness, cutting forces, cutting power and material removal rate of three coated carbides GC2015 (TiCN-Al₂O₃-TiN), GC4215 (Al₂O₃-Ti(C,N)) and GC1015 (TiN) during the dry turning of AISI4140 steel. For this purpose, a Taguchi design (L₉) was adopted for the planning of the experiments, the effects of cutting parameters on the surface roughness (R_a), tangential cutting force (F_z), the cutting power (P_c) and the material removal rate (MRR) were studied using analysis of variance (ANOVA), the response surface methodology (RSM) was used for mathematical modeling, with which linear mathematical models were developed for forecasting of R_a, F_z, P_c and MRR as a function of cutting parameters (V_c, f, and a_p). Then, Multi-Objective Ant Lion Optimizer (MOALO) has been implemented for multi-objective optimization which allows manufacturers to enhance the production performances of the machined parts. Furthermore, in order to characterize and quantify the flank wear of the tested tools, some machining experiments were performed for 5 minutes of turning under a depth of 0.5 mm, a feed rate of 0.08 mm/rev, and a cutting speed of 350 m/min. The wear results led to a ratio (V_B-GC4215/V_B-GC2015) of 2.03 and (V_B-GC1015/V_B-GC2015) of 4.43, thus demonstrating the efficiency of the cutting insert GC2015. Moreover, SEM analysis shows the main wear mechanisms represented by abrasion, adhesion and chipping.

• Journal of the Korean Society for Heat Treatment
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• v.5 no.4
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• pp.215-223
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• 1992

This study has been performed to investigate into some effects of temperature, gas mixing ratio and time on the optical microstructure, hardness and wear characteristics of medium carbon alloy steel treated by plasma nitriding. The results obtained from the experiment are summarized as follows: (1) Optical micrographs of AISI 4140 steel plasma-nitrided by the double stage technique have revealed that the nitrided layer is composed of the compound layer and the diffusion layer. The variation in temperature at the first stage gives effects, on the formation of compound layer and the growth rate is shown to be relatively fast at $460^{\circ}C$. (2) The thickness of compound layer has been found to increase with increasing nitrogen percentage in the gas mixture and the holding time. It is therefore recommended that a shorter holding time and a lower nitrogen percentage are more effective to produce a tougher compound layer and a diffusion layer only. (3) X-ray diffraction analysis for AISI 4140 steel has shown that the compound layer consist of ${\gamma}^{\prime}-Fe_4N$ and ${\alpha}-Fe$ and that tough compound layer diffustion layer only can be obtained by the double stage plasmanitriding process. (4) There is also a tendency that the total hardened layer depth increases with increasing temperature, time and nitrogen percentage in the first stage during the double stage plasma nitriding. (5) The wear resistance of plasma nitrided specimens has been found thobe considerably increased compared to the untreated specimens and the amount of increment has appeared to increase further with increasing nitriding temperature, holding time and notrogen percentage of gas mixture in the first stage treatment.

• Steel and Composite Structures
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• v.32 no.3
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• pp.305-312
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• 2019

In this study, we investigated the effect of fatigue crack propagation of the beams which have a vital importance in engineering applications, on the natural frequency of the system. Beams which have a wide range of applications, are used as fundamental structural elements in engineering structures. Therefore, early detection of any damages in these structures is of vital importance for the prevention of possible destructive damages. One of the widely used methods of early detection of damages is the vibration analysis of the structure. Hence, it is of vital importance to detect and monitor any changes in the natural frequencies of the structure. From this standpoint, in this study we experimentally investigated the effect of fatigue crack propagation on beams produced from 4140 steel, of the natural frequency of the beam. A crack was opened on the $8{\times}16{\times}500mm$ beam using a 3 mm long and 0.25 mm wide wire erosion. The beam, then, underwent 3 point bending tests at 10 Hz with a dynamic fatigue device and its natural frequencies were measured in scheduled intervals and any changes taking place on the natural frequencies of the beam were measured. This data allowed us to identify and measure the crack occurring on the beam subjected to dynamic loading, during the propagation phase. This method produced experimental data. The experimental data showed that the natural frequency of the beam decreased with the propagation of the fatigue crack on the beam.

• Korean Journal of Materials Research
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• v.33 no.3
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• pp.106-114
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• 2023

The carbon concentration in the carburized steels was measured by electron probe microanalysis (EPMA) for a range of soluted carbon content in austenite from 0.1 to 1.2 wt%. This study demonstrates the problems in carbon quantitative analysis using the existing calibration curve derived from pure iron (0.008 wt%C) and graphite (99.98 wt%C) as standard specimens. In order to derive an improved calibration curve, carbon homogenization treatment was performed to produce a uniform Kα intensity in selected standard samples (AISI 8620, AISI 4140, AISI 1065, AISI 52100 steel). The trend of detection intensity was identified according to the analysis condition, such as accelerating voltage (10, 15, 30 keV), and beam current (20, 50 nA). The appropriate analysis conditions (15 keV, 20 nA) were derived. When the carbon concentration depth profile of the carburized specimen was measured for a short carburizing time using the improved calibration curve, it proved to be a more reliable and accurate analysis method compared to the conventional analysis method.