Mechanism of adhesion failure during interrupted cutting with cemented carbide tools: Experimental and ab-initio perspective

Gao, Siyuan; Zheng, M.Y.; Zhu, Jiachen; Chen, Jinguo

doi:10.1016/j.ijrmhm.2021.105549

Cited by 8 publications

(2 citation statements)

References 40 publications

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“…If the flow of the chips affects From this observation, some conclusions can immediately be drawn: (a) the efforts developed in conventional milling are more severe for the substrate and the coating of the tools; (b) the grade of cemented carbide has to be carefully chosen, as if it does not present the required toughness levels, it will lead to catastrophic failure of the tool's sharp edges; (c) in the case of plunge milling, the coating does not compromise the overall behavior of the tool, as the fracture occurs mainly through the substrate; (d) the coating that seems perfectly suited to the plunge milling strategy seems less suitable for the conventional milling strategy; (e) the effect of reducing the adhesion of the machined material to the tool is perfectly achieved with the aid of the coating, which worked almost perfectly in this aspect; (f) the adhesion strength of the coating to the substrate and its abrasion resistance can be improved further by improving the deposition parameters. Gao et al [51] attributed the catastrophic failure of cemented carbide tools in the machining of bonded steels to the formation of Co binder phases with hexagonal closest-packed structures, which induced the formation of segregations and impurities. Also, the thermal cycles are pointed out as one of the main factors for the rapid failure of WC-Co substrates.…”

Section: Analysis Of the Tools Used In Conventional Millingmentioning

confidence: 99%

A Comparative Study of Different Milling Strategies on Productivity, Tool Wear, Surface Roughness, and Vibration

Silva,

Martinho,

Magalhães

et al. 2024

JMMP

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Strategies for obtaining deep slots in soft materials can vary significantly. Conventionally, the tool travels along the slot, removing material mainly with the side cutting edges. However, a “plunge milling” strategy is also possible, performing the cut vertically, taking advantage of the tip cutting edges that almost reach the center of the tool. Although both strategies are already commonly used, there is a clear gap in the literature in studies that compare tool wear, surface roughness, and productivity in each case. This paper describes an experimental study comparing the milling of deep slots in AA7050-T7451 aluminum alloy, coated with a novel DLCSiO500W3.5O2 layer to minimize the aluminum adhesion to the tool, using conventional and plunge milling strategies. The main novelty of this paper is to present a broad study regarding different factors involved in machining operations and comparing two distinct strategies using a novel tool coating in the milling of aeronautical aluminum alloy. Tool wear is correlated with the vibrations of the tools in each situation, the cycle time is compared between the cases studied, and the surface roughness of the machined surfaces is analyzed. This study concludes that the cycle time of plunge milling can be about 20% less than that of conventional milling procedures, favoring economic sustainability and modifying the wear observed on the tools. Plunge milling can increase productivity, does not increase tool tip wear, and avoids damaging the side edges of the tool, which can eventually be used for final finishing operations. Therefore, it can be said that the plunge milling strategy improves economic and environmental sustainability as it uses all the cutting edges of the tools in a more balanced way, with less global wear.

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Section: Analysis Of the Tools Used In Conventional Millingmentioning

confidence: 99%

A Comparative Study of Different Milling Strategies on Productivity, Tool Wear, Surface Roughness, and Vibration

Silva,

Martinho,

Magalhães

et al. 2024

JMMP

View full text Add to dashboard Cite

show abstract

“…At the same time, in actual working conditions, poor toughness has always been a thorny issue limiting the development of cemented carbides. In addition to maintaining excellent hardness, optimal strength and toughness can significantly extend the service life of the cemented carbides [5][6][7][8][9][10][11][12]. Therefore, low-cost, safe and environmentally friendly alloys with high toughness have become the focus of attention in the cemented carbide industry [13][14][15][16].…”

Section: Introductionmentioning

confidence: 99%

The Effect of Carbon Content on the Microstructure and Mechanical Properties of Cemented Carbides with a CoNiFeCr High Entropy Alloy Binder

et al. 2022

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CoNiFeCr high entropy alloy (HEA) was used as a binder in cemented carbides for developing a new high-performance binder. The microstructure of WC-HEA cemented carbides with different binder components and carbon contents was subsequently studied. It was observed that the (Cr,W)C phase precipitated at the WC/HEA interface, and a coherent interface with a low degree of misfit was formed between WC and (Cr,W)C, thereby resulting in a significant reduction in the interfacial energy and stress concentration. The (Cr,W)C phase exerted a pinning force (Zener-drag) on the moving grain boundaries, which effectively inhibited the growth of WC grains. As a result, compared with WC-Co, WC-CoNiFeCr had smaller WC grain size, smoother grain shape and larger mean free path (MFP) of the binder, which resulted in slightly lower hardness and higher transverse rupture strength (TRS) and fracture toughness. The lower limit of carbon content in WC-CoNiFeCr was higher than that of WC-Co. With the addition of Ni, the width of the two-phase region became wider, whereas the width of the two-phase region became narrower with the addition of Fe and Cr.

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Cutting performance and wear mechanism of submicron and ultrafine Ti(C, N)-based cermets

Zhou,

Ouyang,

Kong

et al. 2024

Ceramics International

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Mechanism of adhesion failure during interrupted cutting with cemented carbide tools: Experimental and ab-initio perspective

Cited by 8 publications

References 40 publications

A Comparative Study of Different Milling Strategies on Productivity, Tool Wear, Surface Roughness, and Vibration

A Comparative Study of Different Milling Strategies on Productivity, Tool Wear, Surface Roughness, and Vibration

The Effect of Carbon Content on the Microstructure and Mechanical Properties of Cemented Carbides with a CoNiFeCr High Entropy Alloy Binder

Cutting performance and wear mechanism of submicron and ultrafine Ti(C, N)-based cermets

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