Performance evaluation of modulation-assisted hard turning of AISI 52100 steel

Hard turning is widely used as an alternative to grinding for precision machining of hardened steels, but severe tool wear limits its process efficiency. This study evaluates modulation-assisted machining (MAM) for dry hard turning of 52100 steel (60 HRC) with a TiAlN-coated CBN tool. Compared with conventional turning, MAM significantly reduces tool wear, average cutting forces, and temperature, despite a slight increase in surface roughness. Furthermore, tool wear reduction can be attributed to the formation of dense protective oxide layers on tool rake and flank faces. This study demonstrates the great potential of MAM in enhancing hard turning process efficiency.