Study on cutting performance of SiCp/Al composite using textured YG8 carbide tool

Precision machining of SiCp/Al composites is a challenge due to the existence of reinforcement phase in this material. This work focuses on the study of the textured tools’ cutting performance on SiCp/Al composite, as well as the comparison with non-textured tools. The results show that the micro-pit textured tool can reduce the cutting force by 5–13% and cutting length by 9–39%. Compared with non-textured tools, the cutting stability of the micro-pit textured tools is better. It is found that the surface roughness is the smallest (0.4 μm) when the texture spacing is 100 μm, and the residual stress can be minimized to around 15 MPa in the case of texture spacing 80 μm. In addition, the SiC particles with size of around 2–12 μm in the SiCp/Al composite may play a supporting role between the texture and the chips, which results in three-body friction, thereby reducing tool wear, sticking, and secondary cutting phenomenon. At the same time, some SiC particles enter into the micro-pit texture, so that the number of residual particles on the surface is reduced and the friction between the tool and the surface then decreases, which improves the surface roughness, and reduces the surface residual stress.

Study on cutting performance of SiCp/Al composite using textured tool

In the micro cutting process of SiCp/Al composites, the tool wear is serious due to the existence of reinforcement phase in the material, which greatly affects the machined surface integrity. In order to reduce the friction and adhesion at the tool-chip interface, fabricating micro texture on the tool surface could be a feasible solution. This work focuses on the study of the cutting performance of the textured cutting tools through micro cutting of SiCp/Al composites. The experiments were carried out using NTK-KM1CCGW060202H uncoated cemented carbide tools with micro-hole textures developed by pulsed fiber laser. The results indicate that the micro-textured tools can reduce the wear, sticking and the contact length between the tool-chip. Also, the surface quality can be improved. It is observed from the chip’s surface that the micro-textured tool can produce secondary cutting when machining SiCp/Al composite materials, the smaller the texture spacing, the more obvious the secondary cutting phenomenon. Furthermore, the cutting forces can be reduced using the micro-textured tool in most cases. However, when the texture spacing is too small the cutting force does not decrease. Finally, the surface roughness and surface residual stress of the machined workpiece are investigated. Textured tools have better results.

A review on research progress of machining technologies of carbon fiber-reinforced polymer and aramid fiber-reinforced polymer

Since the application of fiber-reinforced polymer continues to expand, the demands of product quality for secondary cutting process are becoming increasingly higher to ensure the accurate coordination, connection, and assembly. There are some defects such as tearing, burr, delamination, and thermal damage after secondary cutting process, which limit the further applications of the materials. It is urgent to carry out comprehensive research on the secondary processing technology. In this paper, the fiber-reinforced composites' category, characteristics, and their applications were first described. Then the cutting performances, the causes of machining defects, and machining mechanisms have been analyzed. Finally, different compound processing methods, their characteristics, and applications have been elaborated. The most common forms of compound processing method including combined machining of cutting and grinding, ultrasonic vibration–assisted machining, and low-temperature–assisted machining have been covered in this paper. Results show that the compound processing method is the most effective way for improving the second processing quality of fiber-reinforced polymer. More machining mechanisms and applications of compound processing method need further experimental research. The barriers and future in the fields of research on machining of fiber-reinforced composites have been analyzed in this paper.

Untersuchung des Einflusses der Nebenschneiden auf den Reibprozess*/Influence of secondary cutting edges on the reaming process

Präzisionsbohrungen sind aus vielen Branchen nicht wegzudenken, etwa in der Automobilindustrie oder Hydraulik-/Pneumatikbranche. Besonders bei der Serienfertigung von Komponenten des Motorblocks ist das Einbringen von Präzisionsbohrungen unerlässlich. Der Fachaufsatz beschreibt die Modellierung eines Zerspankraftmodells für die Nebenschneiden bei Mehrschneidenreibahlen.   Precision drilling is mandatory in many industries. Typical examples can be found in the automotive, hydraulic or pneumatic industry. Particularly within the mass production of components of the engine blocks the application of precision drilling is essential. This technical paper describes the modeling of a cutting force model for secondary cutting edge at multiblade reamers.

Force Modeling for Generic Profile of Drills

The paper presents a methodology to model the cutting forces by twist drills with generic point geometry. A generic definition of point geometry implies that the cutting lips and the relief surfaces can have arbitrary shapes. Such geometry is easily modeled using Non Uniform Rational B-Spline (NURBS) surface patches which give sufficient freedom to the tool designer to alter the tool geometry. The drill point has three cutting zones: primary cutting lips, secondary cutting lips, and the indentation zone at the center of chisel edge. At the indentation zone, the drill extrudes the workpiece, while at the cutting lips, shearing takes place. At primary cutting lip, the cutting is oblique while at secondary cutting lip, it is predominantly orthogonal. Starting from a computer-aided geometric design of a fluted twist drill with arbitrary point profile, the cutting forces have been modeled separately for all the three cutting zones. The mechanistic method has been employed wherever applicable to have a good correlation between the analytical and the experimental results. The force model has been calibrated and validated for conical drills. Then the model has been evaluated for a drill ground with curved relief surfaces. The theoretical and experimental results are found out to be in good conformity.