Machinability of Stone—Plastic Materials During Diamond Planing

Abstract

This paper investigated the machinability of a stone–plastic composite (SPC) via orthogonal cutting with diamond cutters. The objective was to determine the effect of cutting depth on its machinability, including cutting forces, heat, chip formation, and cutting quality. Increased cutting depth promoted an increase in both frictional and normal forces, and also had a strong influence on the change in normal force. The cutting temperatures of chips and tool edges showed an increasing trend as cutting depth increased. However, the cutting heat was primarily absorbed by chips, with the balance accumulating in the cutting edge. During chip formation, the highest von Mises strain was mainly found in SPC ahead of the cutting edge, and the SPC to be removed partially passed its elastic limit, eventually forming chips with different shapes. Furthermore, the average surface roughness and the mean peak-to-valley height of machined surfaces all positively correlated to an increase in cutting depth. Finally, with an increase in cutting depth, the chip shape changed from tubular, to ribbon, to arc, to segmental, and finally, to helical chips. This evolution in chip shape reduced the fluctuation in cutting force, improving cutting stability and cutting quality.

Machinability of Luxury Vinyl Tiles during Plain Milling Using a Helical Cutter

“…It can also be seen from Figure 2 that the cutting force decreased slightly with the increase of cutting speed, but increased with an increase in cutting depth. The trends of cutting forces with different cutting conditions are similar to results obtained by Zhu et al, when stone-plastic material (a composite material with structure like LVT) was machined by PCD cutters during orthogonal cutting [14,15]. Figure 4 is the schematic diagram of feed per tooth and chip thickness during helical up milling.…”

“…Thus, the poor quality of the machined surface can be associated with temperature increase in the cutting zone [15,18]. Finally, it can be concluded from Figure 5 that the surface roughness increased with the increase of cutting depth, and the changes of LVT’s surface roughness had the same trend to that of stone-plastic material [14]. As described in Section 3.1, the increase of cutting depth enhanced the removal volume per unit time of the cutting tool, which reduced the cutting stability, so the cutting quality decreased with the increase of cutting depth.…”

“…Pramanik et al [12] studied the changes in cutting force and surface roughness when turning electroless-nickel plated die with a diamond cutting tool, wherein they determined that the cutting forces show an increasing trend with the increased spindle speed, feeding rate and cutting depth, while the contribution of cutting depth to surface roughness is insignificant, and the surface roughness first decreases and then increases with the increasing spindle speed. In related studies, Cao et al [13] and Zhu et al [14,15], investigated the machinability of the stone-plastic materials, a composite similar to LVT, and their results showed that the cutting forces and surface roughness show a similar trend under different cutting forces, where they all are positively correlated with cutting depth, but negatively related to cutting speed and rake angles of cutters. Taking cutting force and surface roughness as evaluating indicators, the cutting parameters were optimized by Yalcin et al [16], wherein milling steel, and the optimum selection of cutting parameters importantly contributed to the improvement of the economic benefit and productivity [17].…”

Cutting Force and Cutting Quality during Tapered Milling of Glass Magnesium Board

“…Therefore, the surface roughness increased with an increasing taper angle. Similar to the results of Guo et al [6] and Zhu et al [22], the surface roughness decreased with the increase of spindle speed and increased with an increased cutting depth ( Figure 5). As expressed in Equations (5) and (6), the increasing spindle speed and decreasing cutting depth reduced the feed per tooth and the cutting thickness during the milling process, directly lowering the resistance acting on the cutter and improving the cutting stability.…”

Investigation on Milling Quality of Stone–Plastic Composite Using Response Surface Methodology

“…1 These raw materials are mixed with multiple supportive agents, followed by extrusion under high temperature and pressure. 2 Due to their outstanding physical and chemical properties, SPCs have been widely adopted in decoration and architecture industries as materials to build floors and wall panels. 3 According to the China Forestry Association, about 891 million m 2 of floors were sold in 2019 in China, 44% of which were made from SPCs or related plasticbased materials.…”