Friction behaviors in the metal cutting process: state of the art and future perspectives

Abstract

Material removal in the cutting process is regarded as a friction system with multiple input and output variables. The complexity of cutting friction system is caused by the extreme conditions existing on the tool-chip and tool-workpiece interfaces. The key issue is extremely important to use knowledge of cutting friction behaviors to guide researchers and industrial manufacturing engineers in designing reasonable cutting processes to reduce tool wear and improve surface quality. This review focuses on the state of the art of research on friction behaviors in cutting processes as well as future perspectives. First, the cutting friction phenomena under extreme conditions, such as high temperature, large strain/strain rates, sticking-sliding contact states, and diverse cutting conditions are analyzed. Second, the theoretical models of cutting friction behaviors and the application of simulation technology are discussed. Third, the factors that affect friction behaviors are analyzed including material matching, cutting parameters, lubrication/cooling conditions, micro/nano surface textures and tool coatings. Then, the consequences of the cutting friction phenomena including tool wear patterns, tool life, chip formation, and the machined surface are analyzed. Finally, the research limitations and future work for cutting friction behaviors are discussed. This review contributes to the understanding of cutting friction behaviors and the development of high-quality cutting technology.

Study on friction reduction performance of granular flow lubrication during the milling of Inconel 718 superalloy

“…As for dry cutting, the absence of lubricant gives rise to severe deformation and friction, resulting in larger cutting forces and higher cutting temperatures. Therefore, the adhesive damage is more likely to appear on the machined surface and deteriorate surface quality (Liang et al , 2022). As for flood lubrication, the applicable temperature range for the emulsion is usually 60°C∼350°C.…”

Design and optimization of fluid lubricated bearings operated with extreme working performances—a comprehensive review

“…The bearing performances of large-scale hydrostatic bearings are greatly affected by manufacturing errors and slight changes in the lubricating film. The manufacturing procedure introduces errors other than structural deformations [183]. Harmonic wave errors on deformed hydrostatic bearings are of the same order of magnitude as the film thickness (figure 28) [184].…”

Cyber–Physical Systems for High-Performance Machining of Difficult to Cut Materials in I5.0 Era—A Review

“…The contact friction model determines the frictional stresses acting on the rack and flack faces [67]. Friction models such as the constant shear friction factor for the whole cutting contact length and the constant shear friction factor for the sticking zone along with a constant friction coefficient for the sliding zone are the main simplified approaches that are implemented in machining FE simulations.…”