Evaluation of methods for measuring tool-chip contact length in wet machining using different approaches (microtextured tool, in-situ visualization and restricted contact tool)

Abstract

The contact length is one of the most important factors to evaluate the chip formation process and the mechanical loads in metal cutting. Over the years, several methods to identify the contact length were developed. However, especially for wet cutting processes the determination of the contact length is still challenging. In this paper, three methods to identify the contact length for dry and wet processes in cutting of Ti6Al4V and AISI4140 + QT are presented, discussed and analyzed. The first approach uses tools with a microtextured rake face. By evaluating the microstructures on the chip, a new method to identify the contact length is established. The second approach applies high speed recordings to identify the contact length. The challenge is thereby the application of high-speed recordings under wet conditions. In the third approach, tools with restricted contact length are used. It is shown that with all three methods the contact length is reduced using metal working fluid.

Mechanical influence on the chip formation in wet metal cutting

“…This leads to an increase in the normal stresses on the rake face [11]. Ellersiek et al show a reduction in contact length during wet machining using various methods [12]. This showed a general decrease of the reduction in contact length with an increase in pressure.…”

Effect of Composite Bionic Micro-Texture on Cutting Performance of Tools

“…Salem, A, et al investigated ways to improve the surface quality of the machined workpiece under dry cutting conditions by using micro-textures. The study found that when cutting AISI 10 steel at different cutting speeds, micro-textures on the tool's surface reduced the length of contact between the tool and the chip, thus helping to reduce the cutting force and cutting heat [11]. Fouathiya et al studied the micro-texturing of tools used to process titanium alloys and found that micro-texturing processes were more efficient during processing when microstructural types were crosslinked.…”