Experimental study of Built-Up Layer formation during machining of high strength free-cutting steel

Desaigues, Jean-Edouard; Lescalier, Christophe; Bomont-Arzur, Anne; Dudzinski, D.; Bomont, Olivier

doi:10.1016/j.jmatprotec.2016.05.016

Cited by 20 publications

(7 citation statements)

References 21 publications

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“…Oliaei and Karpat [17] studied microscale machining of titanium alloy via micro turning tests and reported the protective effect to stable BUE on the tool. A closely related issue to BUE is the built-up layer (BUL), which is defined as the material accumulation on the rake face of the tool [18,19]. It has been shown that during dry titanium machining, a BUL first forms on the rake face, which then gives rise to BUE formation at the tool tip [14].…”

Section: Introductionmentioning

confidence: 99%

Investigating the influence of friction conditions on finite element simulation of microscale machining with the presence of built-up edge

Oliaei

2016

Int J Adv Manuf Technol

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In micromachining, the uncut chip thickness is less than the cutting tool edge radius, which results in a large negative effective rake angle. Depending on the material properties, this large negative rake angle promotes built-up edge (BUE) formation. A stable BUE acts like a cutting edge and affects the mechanics of the process. The size of the BUE increases with increasing uncut chip thickness and cutting speed. It also creates a positive rake angle, but it decreases the clearance angle of the tool. A method of including BUE formation in finite element simulations is to use sticking friction conditions at the tip of the tool. However, this approach is shown to be insufficient to simulate BUE formation in microscale machining. Therefore, the cutting edge is modified with the experimental BUE size in the finite element simulations based on experimental measurements. The influence of friction models between BUE and the work material has been investigated, and the study identifies friction coefficients that yield good agreements with experimental results. The finite element model is shown to be capable of simulating process forces and chip shapes for uncut chip thickness values larger than minimum uncut chip thickness.

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Section: Introductionmentioning

confidence: 99%

Investigating the influence of friction conditions on finite element simulation of microscale machining with the presence of built-up edge

Oliaei

2016

Int J Adv Manuf Technol

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“…Here, MB had the lowest value of average friction coefficient, which indicated that the free-cutting steel with Bi addition showed the best friction characteristics. Based on previous studies, [6][7][8] it is mainly due to the inclusions formed in the steel, which presented a better performance in chip breaking and lubricant layer forming. ME had the worst average friction coefficient, which indicated that the friction characteristics on the tool-chip interface were poor.…”

Section: Friction Characteristics and Shear Anglementioning

confidence: 99%

Study on the tool life analysis for free-cutting steels

Zhang

Yang

Tang

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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Experimental study and theoretical calculation on the tool lives of free-cutting steels with different additions were carried out in terms of the friction characteristics, chip deformation, and normal stress distribution. The average friction coefficient, shear angle, and maximum normal stress were then calculated, and the influence of them on tool life was analyzed and discussed carefully. The free-cutting steel with Bi addition (MB) presented the best tool life of about 9200 and 5200 s at the speed of 150 and 200 m/min, respectively, which was mainly due to the combined effect of the lower average friction coefficient, maximum normal stress, and higher shear angle. When the cutting speed increased to 300 m/min, the tool life decreased rapidly, which was mainly caused by the serious tool wear behavior dominated by the high cutting temperature. Differing from the calculated results of shear angles based on Lee and Shaffer’s assumption, the measured shear angles decreased with the cutting speed ranging from 150 to 250 m/min, resulting from the thermal softening of workpiece material during machining. Moreover, the present findings indicated that the cutting process became unstable when the maximum normal stress on the tool nose was larger than 2 GPa, where catastrophic failures occurred, resulting in accelerated fracture of the tool. The research findings not only give more insight into the effect of friction characteristics, chip deformation, and normal stress distribution on the tool lives, but also have significance for the machining of free-cutting steels.

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“…(Trent and Wright, 2000). The formations of built-up edge (BUE) and built-up layer (BUL) on the cutting insert are caused by excessive pressure and chip-tool interface temperature (Desaigues et al, 2016). Among the effects of tool wear, the most important one is flank wear (Blais et al, 2001).…”

Section: Tool Lifementioning

confidence: 99%

Factors Influencing the Machinability during Turning Sinter-Hardened Cu-Ni-Mo Based Steel: Dependency on Cutting Speed, Feed Rate, and Cutting Depth

Üllen

Hasak

Dirikolu

2020

Journal of Engineering Research is an international, peer-revie

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Machinability of sintered parts is a complex phenomenon influenced by a number of factors, including workpiece and tool properties, cutting conditions, and cutting parameters. A better understanding of the influence of all these parameters on the machinability of sinter-hardened Cu-Ni-Mo based steels is essential. This work uses an output matrix of surface roughness, chip formation, cutting forces, and tool wear to assess the machinability of sintered parts. Cutting speeds of 50, 150, and 250 m/min, feed rates of 0.05, 0.1, and 0.15 mm/rev, and cutting depths of 0.2, 0.4, and 0.6 mm were systematically used as cutting parameters. The results indicated that short spiral chips were formed in all cutting parameters and that the higher feed rates and cutting depth increase the forces and deteriorate surface quality. The increase in cutting speed increases the forces, while linearly decreasing the tool life; however, it has a positive effect on the surface finish.

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Experimental study of Built-Up Layer formation during machining of high strength free-cutting steel

Cited by 20 publications

References 21 publications

Investigating the influence of friction conditions on finite element simulation of microscale machining with the presence of built-up edge

Investigating the influence of friction conditions on finite element simulation of microscale machining with the presence of built-up edge

Study on the tool life analysis for free-cutting steels

Factors Influencing the Machinability during Turning Sinter-Hardened Cu-Ni-Mo Based Steel: Dependency on Cutting Speed, Feed Rate, and Cutting Depth

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