The Influence of Bionic Micro-Texture’s Surface on Tool’s Cutting Performance

2016 ◽  
Vol 693 ◽  
pp. 1155-1162
Author(s):  
Feng Xie ◽  
Xiao Bao Lei
Keyword(s):  
Cutting Forces ◽  
Laser Processing ◽  
Cutting Tool ◽  
Orthogonal Cutting ◽  
Cutting Performance ◽  
Processing Technology ◽  
Good Effect ◽  
Rake Face ◽  
Carbide Tool ◽  
Friction Property

Related researches of bionic tribology indicate that reasonable bionic micro-texture’s surface has a good effect on tool’s anti-friction property. In order to study bionic micro-texture effects on tools’ cutting performance further, in this paper groove and scallop micro-texture are made out on the surface of carbide tool with laser processing technology. Then orthogonal cutting tests are made to cut steel 45 in dry or wet cutting with different feedings. The results show that cutting forces can be effectively reduced by the cutting tool with micro-texture’s surface. Especially, the micro-texture’s tool has the best effect when the direction of grooves is vertical to the direction of chip’s motion, and the wear degree of its rake face is also slighter. All of those will be helpful to guide the design of cutting tool.

Frictional interactions between chip and rake face in continuous chip formation

1979 ◽  
Vol 366 (1725) ◽  
pp. 173-183 ◽  
Keyword(s):  
Cutting Forces ◽  
Single Phase ◽  
Cutting Tool ◽  
Orthogonal Cutting ◽  
Cutting Edge ◽  
Rake Face ◽  
Relative Movement ◽  
Intimate Contact ◽  
Cubic Materials ◽  
Continuous Chip

A transparent sapphire cutting tool is used to study directly the frictional interactions occurring at the chip–tool interface. The investigation deals with the orthogonal cutting of single phase, face-centred cubic materials, in air and in vacuum. The investigation brings out two points of importance. First, although there is intimate contact between the chip and the tool in the immediate vicinity of the cutting edge, there is relative movement at the chip–tool interface with little or no adhesive transfer of chip material in this region. Secondly, in each of the systems examined it was found that oxygen increased the cutting forces. This increase was associated with the gross transfer of chip material onto the cutting tool at some distance away from the cutting edge.

scholarly journals Preparation and cutting performance of nano-scaled Al2O3-coated micro-textured cutting tool prepared by atomic layer deposition

2021 ◽  
Vol 40 (1) ◽  
pp. 77-86
Author(s):  
Siwen Tang ◽  
Pengfei Liu ◽  
Zhen Su ◽  
Yu Lei ◽  
Qian Liu ◽  
...  
Keyword(s):  
Friction Coefficient ◽  
Atomic Layer Deposition ◽  
Cutting Force ◽  
Cutting Tool ◽  
Orthogonal Cutting ◽  
Cutting Tools ◽  
Atomic Layer ◽  
Cutting Performance ◽  
Cutting Test ◽  
Layer Deposition

Abstract Al2O3 nano-scaled coating was prepared on micro-textured YT5 cemented carbide cutting tools by atomic layer deposition ALD. The effect of Al2O3 nano-scaled coating, with and without combined action of texture, on the cutting performance was studied by orthogonal cutting test. The results were compared with micro-textured cutting tool and YT5 cutting tool. They show that the micro-texture and nano-scaled Al2O3 coated on the micro-texture both can reduce the cutting force and friction coefficient of the tool, and the tools with nano-scaled Al2O3 coated on the micro-texture are more efficient. Furthermore, the friction coefficient of the 100 nm Al2O3-coated micro-texture tool is relatively low. When the distance of the micro-pits is 0.15 mm, the friction coefficient is lowest among the four kinds of pit textured nanometer coating tools. The friction coefficient is the lowest when the direction of the groove in strip textured nanometer coating tool is perpendicular to the main cutting edge. The main mechanism of the nanometer Al2O3 on the micro-textured tool to reduction in cutting force and the friction coefficient is discussed. These results show that the developed tools effectively decrease the cutting force and friction coefficient of tool–chip interface.

Improving Tool Wear Resistance in Inconel 718 Cutting by Considering Surface Microstructures of CBN Cutting Tool

2016 ◽  
Vol 1136 ◽  
pp. 561-566
Author(s):  
Tatsuya Sugihara ◽  
Shota Takemura ◽  
Toshiyuki Enomoto
Keyword(s):  
Wear Resistance ◽  
Inconel 718 ◽  
Cutting Tool ◽  
Orthogonal Cutting ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Polished Surface ◽  
Rake Face ◽  
Crater Wear ◽  
Surface Microstructures

Nickel-based superalloys such as Inconel 718 are known as one of the most difficult-to-cut materials due to their mechanical and chemical properties and the tool life is extremely short. Recently, Cubic-Boron-Nitride (CBN) has received a considerable attention as a material for cutting tools and has been considered to be a major candidate for high performance cutting of Inconel 718. However, the detailed wear behavior of CBN tools in cutting of Inconel 718 is not sufficiently understood yet, and the performances of CBN tools are still insufficient in practical use. To overcome this problem, we first conducted orthogonal cutting experiments on Inconel 718 at low (20 m/min) and high (100 m/min) cutting speeds employing CBN cutting tools to clarify the detailed wear mechanisms. Moreover, relationship between surface microstructures of the cutting tool and wear resistance was investigated. As a result, it was found that a rake face with micro grooves significantly suppressed the crater wear at low cutting speed, although polished surface rake face reduced the initial crater wear by approximately 40 % compared to the non-polished tool in high speed cutting of Inconel 718.

Finite Element Modeling of Edge Trimming Fiber Reinforced Plastics

2000 ◽  
Vol 124 (1) ◽  
pp. 32-41 ◽  
Author(s):  
D. Arola ◽  
M. B. Sultan ◽  
M. Ramulu
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Deformable Body ◽  
Orthogonal Cutting ◽  
Element Model ◽  
Tool Geometry ◽  
Reinforced Plastics ◽  
Edge Trimming

A finite element model was developed to simulate chip formation in the edge trimming of unidirectional Fiber Reinforced Plastics (FRPs) with orthogonal cutting tools. Fiber orientations (θ) within the range of 0 deg⩽θ⩽90 deg were considered and the cutting tool was modeled as both a rigid and deformable body in independent simulations. The principal and thrust force history resulting from numerical simulations for orthogonal cutting were compared to those obtained from edge trimming of unidirectional Graphite/Epoxy (Gr/Ep) using polycrystalline diamond tools. It was found that principal cutting forces obtained from the finite element model with both rigid and deformable body tools compared well with experimental results. Although the cutting forces increased with increasing fiber orientation, the tool rake angle had limited influence on cutting forces for all orientations other than θ=0 deg and 90 deg. However, the tool geometry did affect the degree of subsurface damage resulting from interlaminar shear failure as well as the cutting tool stress distribution. The finite element model for chip formation provides a means for optimizing tool geometry over the total range in fiber orientations in terms of the cutting forces, degree of subsurface trimming damage, and the cutting tool stresses.

Effect of conical micro-grooved texture on tool–chip friction property and cutting performance of WC-TiC/Co cemented carbide tools

2018 ◽  
Vol 233 (5) ◽  
pp. 791-804
Author(s):  
Minghua Pang ◽  
Xiaojun Liu ◽  
Kun Liu
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Metal Cutting ◽  
Cutting Performance ◽  
Cemented Carbide ◽  
Cutting Fluid ◽  
Rake Face ◽  
Friction Property ◽  
Cemented Carbide Tools ◽  
Tool Cutting

Purpose This study aimed to clarify the influence mechanism of conical micro-grooved texture on the tool–chip friction property and cutting performance of WC-TiC/Co cemented carbide tools under flood lubrication conditions. Design/methodology/approach Conical micro-grooved texture was fabricated on the tool rake face using laser texture technology. Metal cutting tests were conducted on AISI 1045 steel with conventional and developed tools for various cutting speeds (80 m/min to 160 m/min) and conical angles of micro-grooved texture (2 ° to 5 °) under flood lubrication condition. The effect of conical micro-grooved texture on the tool cutting force, tool–chip friction coefficient, surface roughness of the machined workpiece, and wear of the tool rake face was determined. Findings Unlike the conventional tools, the conical micro-grooved tools successfully resulted in reductions in metal cutting force, tool–chip frictional coefficient, surface roughness of the machined workpiece, and wear of the tool rake face. These reductions were more noticeable than those of conventional tools with increases in the cutting speed and conical angle of the micro-grooved texture. Detailed research indicated that conical micro-grooved channel exhibits a directional motion characteristic of liquid, which accelerated the infiltration of cutting fluid at the tool–chip interface. Substantial cutting fluid was supplied and stored at the tool–chip interface for the conical micro-grooved tools. Therefore, the conical micro-grooved texture on the tool rake face showed evident advantages in improving tool–chip friction and tool cutting performance. Originality/value The main contribution of this study is proposing a new conical micro-grooved texture on the tool rake face, which improved tool–chip friction and tool cutting performance.

A New Experimental Setup and Method to Analyze Cutting Forces in Non-Stationary Conditions

2011 ◽  
Vol 223 ◽  
pp. 679-688
Author(s):  
Sajid Yaqub ◽  
Arnaud Larue ◽  
Gerard Coffignal
Keyword(s):  
Cutting Forces ◽  
Cutting Tool ◽  
Orthogonal Cutting ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Experimental Setup ◽  
Process Damping ◽  
Flexible Workpiece ◽  
Vibration Drilling ◽  
Set Up

The numerical simulation of machining, when dealing with flexible workpieces, still needs to be improved by the introduction of more accurate cutting force models. The aim of this paper is to propose a general method which is designed to generate transient cutting forces and severe cutting conditions including process damping to be able to set up cutting laws in these cases. In this first approach, the method is limited to orthogonal cutting. The method is based on a special design of a very simple "flexible workpiece" where slots have been introduced in the machined area to get an intermittent cutting. The exibility of the workpiece induces axial vibrations like it is done in vibration drilling and the presence of slots leads to cutting conditions similar to those of milling. The proposed testing device has been designed to be flexible along one degree of freedom, while the cutting tool is considered as rigid. This allows to generate cutting conditions where the axial depth of cut fluctuates as well as the contact between the cutting tool and the workpiece. The experimental setup allows the measurement of cutting forces and the simultaneous measurement of the relative tool/workpiece displacements. The measured signals and numerical interpretations of the machining operation allow to compare a proposed cutting law with the experimental results. The cutting law parameters can then be optimized, even when process damping occurs. The paper introduces a first application of the proposed method.

Performance of Carbide Tools with Micro-Texture on Titanium Alloys Cutting in Dry Conditions

2012 ◽  
Vol 590 ◽  
pp. 17-22 ◽  
Author(s):  
Chen Chen ◽  
Yong Jie Chen ◽  
Ning Li ◽  
Yang Liu
Keyword(s):  
Titanium Alloys ◽  
Mechanical Model ◽  
Cutting Tool ◽  
Minimum Quantity Lubrication ◽  
Cutting Parameters ◽  
Good Effect ◽  
Rake Face ◽  
Business Software ◽  
Average Coefficient ◽  
Dry Conditions

Hard machinability of titanium alloys severely limits its development in the field of aviation. It has been proved that micro-texture has a good effect on friction-reducing in turning under the conditions of Minimum Quantity Lubrication (MQL). In this paper, cutting tool with micro-texture on its rake face is fabricated and then experiments are carried out under the conditions of dry continuous turning titanium alloys. A dynamometer is set under the workpiece to measure three components of the cutting forces and the data is processed by Business software MATLAB. Average coefficient μ is calculated according to the mechanical model. Experimental results show that under the dry conditions, micro-texture plays a role in the specific cutting parameters while losing its role in most cases. Also the reasons which lead to the failure of improving the friction properties are analyzed.

Effect of Tool Flank Wear on the Orthogonal Cutting Process

2007 ◽  
Vol 329 ◽  
pp. 705-710 ◽  
Author(s):  
X.L. Zhao ◽  
Yong Tang ◽  
Wen Jun Deng ◽  
F.Y. Zhang
Keyword(s):  
Cutting Forces ◽  
Cutting Tool ◽  
Flank Wear ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Element Model ◽  
Cutting Process ◽  
Temperature Fields ◽  
Tool Flank Wear ◽  
Chip Separation

A coupled thermoelastic-plastic plane-strain finite element model is developed to study orthogonal cutting process with and without flank wear. The cutting process is simulated from the initial to the steady-state of cutting force and cutting temperature, by incrementally advancing the cutting tool forward. Automatic continuous remeshing is employed to achieve chip separation at the tool tip regime. The effect of the degree of the flank wear on the cutting forces and temperature fields is analyzed. With the flank wear increasing, the maximum cutting temperature values on the workpiece and cutting tool increase rapidly and the distribution of temperature changes greatly. The increase of tool flank wear produced slight increase in cutting forces but significant increase in thrust forces.

The Numerical Investigation of Stress Distribution on the Rake Face for Grooved Cutting Tool Inserts

2011 ◽  
Vol 223 ◽  
pp. 304-313
Author(s):  
E. Kwiatkowska ◽  
Piotr Niesłony ◽  
W. Grzesik
Keyword(s):  
Metal Cutting ◽  
Cutting Tool ◽  
Orthogonal Cutting ◽  
Cutting Tools ◽  
Cutting Process ◽  
Rake Face ◽  
Normal Stresses ◽  
Von Mises ◽  
Von Mises Stresses ◽  
Chip Breakage

The development of an accurate model for the shear and normal stresses on the rake face is very important for modeling of the metal cutting mechanics. It is known that the stresses vary over the contact surfaces of the tool and change substantially with their configurations. On the other hand, the recent attempts were generally addressed to orthogonal cutting process and tools with flat rake faces. At present, grooved tools with complex rake faces are commonly applied in the industry. In this study a plane strain finite element (FEM) program AdvantEdge was used to simulate the cutting process with some disposable grooved cutting tools. Both the reduced von Mises stresses and their components in x and y directions were considered and visualized for appropriate chip formation stages. In particular, the distribution of the contact stresses was revealed when chip breakage occurs. The simulated results were correlated with the geometry of the chip breaker and process parameters.

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