Chipping and Breakage of Carbide Tools

Abstract

The paper deals with chipping and breakage of carbide tools and it is based on a combination of turning tests, examination of fracture surfaces, and analysis of stresses in the tool as produced by the cutting force. Thermal stresses are so far not considered. It is concluded that chipping is a ductile failure due to high shear stresses at the cutting edge and breakage is brittle fracture originating at the rake face at a local maximum of tensile stress. For the finite element stress analysis, a new method of successively refining mesh while diminishing the analyzed area is introduced which is rather effective and economical in that all computation except for the final field is done once only for various loading cases.

Burr minimization in face milling: an edge bevelling approach

“…Tseng and Chiou [31] adopted an experimental approach based on the Taguchi method to explore the size and type of burr formed under different cutting conditions. The work on the minimization of burr formation reported by Uchara [32], Tlusty and Masood [33], van Luttervelt et al [34], and Pekerling [35], led to the suggestion that tool failure might occur due to the continuous variation of chip load and mechanical shock at the entry and exit of the cutter. Gardner and Vijayaraghavan [36] reported attempts to use the finite-element analysis approach to understand burr formation.…”

Simulation of accompanying phenomena in the cutting zone during drilling of stainless steels

“…zone, hFZ is the depth of the flow zone, hpD is the depth of the plastically-deformed material, hPD=hI+hII , hh is the depth of the hardened machined surface and hsp is the depth of the shear layer [1], [4]. The thickness of the cut layer continually varies chip thickness hI' Chip formation is described through the theory of plasticity, [2], [9]. The strain line field extended to the region of plastic deformation, the machined surface, and the cut layer (the chip).…”

“…Strain lines represent an extensive high intensity deformation. The process of cutting is the mutual interaction between the tool and the workpiece, which is controlled by many phenomena, which creates a synergistic effect, [2], [8]. Damage to the cutting edge of the tool in conditions greater than cutting speed vc=80 mlmin and feedj=0.12 mm per rev.…”

A unified optimization model of a machining process for specified conditions of machined surface and process performance

“…In addition, we can use a group of remote thermocouples at the rear of the insert and use the known data from the well-established metallographic methods (Yen and Wright 1983, Trent 1977, Wright and Trent 1974. In order to extrapolate the measured temperature to the cutting edge temperature or crater zone temperature for estimating the crater wear, flank wear and plastic deformation of the cutting tool, a finite element method was proposed by Tlusty (1978). Strain gauge and piezoelectric dynamometers are the most commonly used force sensors, which are simple and reliable in measuring the cutting forces.…”