Cutting Forces in Machining of Low-Lead and Lead-Free Brass Alloys

Müller, Magdalena S.; Sørby, Knut

doi:10.1007/978-981-19-0572-8_32

Cited by 2 publications

(5 citation statements)

References 7 publications

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“…Additionally, the cutting forces and the force ratio were overall higher for the coated tools. The roughness of the coated tools was around 0.05 µm, while the roughness of the uncoated tools was around 0.01 µm, which could have led to the increase in cutting force components and friction in the cutting zone [12]. The coating is in the literature described to reduce friction in brass [15].…”

Section: Resultsmentioning

confidence: 99%

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The Effect of Tool Geometry on Chip Formation and Chip Morphology of Lead-Free Brass Alloy CW511L

Müller,

Sørby

2023

Preprint

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Lead as an alloying element in brass is legally restricted. Investigations to adapt to the properties of lead-free brass alloys in machining are necessary. The main problems in machining lead-free brass alloys are increased cutting forces and long snarled chips. This paper investigates the impact of the rake angle and different chip-breaking geometries on the chip breakability of the lead-free brass alloy CW511L (CuZn38As). Orthogonal cutting tests were conducted on a lathe. Cutting force measurements, chip analysis, and high-speed camera recordings were performed to analyze the cutting process. The camera recordings were used to analyze the chip formation process with tools with varying chip-breaking geometries. Chips were investigated in microscopic studies. An increased rake angle led to increased chip length but decreased cutting forces. A chip-breaking geometry with a restricted contact length could help to counteract the negative impact of a positive rake angle on the chip breakability with only a marginal effect on the cutting forces. It is crucial to choose a chip-breaking geometry following the cutting parameters. Out of the investigated tools, a tool with a chip breaker land width of 0.7 mm and a groove radius of 3.5 mm was the most beneficial regarding the chip breakability.

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Section: Resultsmentioning

confidence: 99%

“…In the first series of tests, the rake angle was varied to investigate the influence on the chip formation 4. A detailed analysis of the tool geometry is presented by Müller and Sørby [12].…”

Section: Experimental Designmentioning

confidence: 99%

The Effect of Tool Geometry on Chip Formation and Chip Morphology of Lead-Free Brass Alloy CW511L

Müller,

Sørby

2023

Preprint

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“…While machinability depends on the properties of the material as well as the selected process parameters and process boundary conditions, most studies have focused on optimizing machinability on the process side. For example, there is a large number of research papers that have dealt with the tool and process design for turning, drilling, or milling of lead-free CuZn-alloys [2,[4][5][6][7][8][9][10][11][12][13][14]. Consequently, there is a broad knowledge of how to adapt tools and processes for the machining of existing leadfree CuZn-alloys.…”

Section: Introductionmentioning

confidence: 99%

“…In machining, the use of Si-containing CuZn-alloys is associated with increased tool wear due to the highly abrasive κ-phase [2]. In addition, the influence of mechanical material properties and the microstructural properties of lead-free CuZn-alloys on machinability was investigated in the past [5,[22][23][24][25][26][27]. Hofmann et al used low lead CuZnalloys to investigate whether a reduced mass fraction of lead can be compensated for and whether satisfactory chip-breaking behavior can be achieved by adjusting certain material properties (strength, ductility, and microstructure) [28].…”

Section: Introductionmentioning

confidence: 99%

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Influence of the Material Production Route on the Material Properties and the Machinability of the Lead-Free Copper-Zinc-Alloy CuZn40 (CW509L)

Brans,

Kind,

Meurer

et al. 2024

Metals

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To improve the machinability properties of CuZn-alloys, these are alloyed with the element lead. Due to its toxicity, a variety of legislative initiatives aim to reduce the lead content in CuZn-alloys, which results in critical machinability problems and a reduction in the productivity of machining processes. Basically, there are two ways to solve the critical machinability problems when machining lead-free CuZn-alloys: optimizing the machinability of lead-free materials on the material side or adapting the processes and the respective process parameters. In this study, the focus is on material-side machinability optimization by investigating the influence of a targeted variation in the process chain in the material production route. To evaluate the influence of the material production route, the brass alloy CuZn40 (CW509L) was produced in four variants by varying the degree of work hardening and the use of heat treatments, and all four variants were evaluated in terms of their machinability. To evaluate the machinability, the cutting force components, the chip temperature, the chip formation, and the chip shape were analyzed. Clear influences of the material production route were identified, particularly with regard to the chip formation mechanisms and the resulting chip shape.

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Cutting Forces in Machining of Low-Lead and Lead-Free Brass Alloys

Cited by 2 publications

References 7 publications

The Effect of Tool Geometry on Chip Formation and Chip Morphology of Lead-Free Brass Alloy CW511L

The Effect of Tool Geometry on Chip Formation and Chip Morphology of Lead-Free Brass Alloy CW511L

Influence of the Material Production Route on the Material Properties and the Machinability of the Lead-Free Copper-Zinc-Alloy CuZn40 (CW509L)

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