Metallurgical Analysis of Chip Forming Process when Machining High Strength Bainitic Steels

Haddad, Fares; Lescalier, Christophe; Desaigues, Jean-Edouard; Bomont-Arzur, Anne; Bomont, Olivier

doi:10.3390/jmmp3010010

Cited by 2 publications

(1 citation statement)

References 20 publications

(20 reference statements)

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“…Given their high performance under severe working conditions, via mechanical and thermal stresses and harsh chemical environments [1,2], superalloys and advanced materials have been widely used in the manufacturing of components for jet engines [2], turbochargers [3] and aerospace [4] applications. Nevertheless, these materials display difficult machinability characteristics [5,6] due to their low thermal diffusivity [2], high strain hardening [7], high chemical reactivity [8], carbide precipitation in grain boundaries [1] and high ductility [9]. Chief among these machining attributes, the high ductility of machined workpieces ordinarily leads to the formation of long continuous chips during the machining process, which negatively affects the safety, efficiency and continuity of the machining operation [10].…”

Section: Introductionmentioning

confidence: 99%

Tailored Chip Breaker Development for Polycrystalline Diamond Inserts: FEM-based Design and Validation

Cascón¹,

Sarasua²,

Elkaseer³

2019

Applied Sciences

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Chip evacuation is a critical issue in metal cutting, especially continuous chips that are generated during the machining of ductile materials. The improper evacuation of these kinds of chips can cause scratching of the machined surface of the workpiece and worsen the resultant surface quality. This scenario can be avoided by using a properly designed chip breaker. Despite their relevance, chip breakers are not in wide-spread use in polycrystalline diamond (PCD) cutting tools. This paper presents a systematic methodology to design chip breakers for PCD turning inserts through finite element modelling. The goal is to evacuate the formed chips from the cutting zone controllably and thus, maintain surface quality. Particularly, different scenarios of the chip formation process and chip curling/evacuation were simulated for different tool designs. Then, the chip breaker was produced by laser ablation. Finally, experimental validation tests were conducted to confirm the ability of this chip breaker to evacuate the chips effectively. The machining results revealed superior performance of the insert with chip breaker in terms of the ability to produce curly chips and high surface quality (Ra = 0.51–0.56 µm) when compared with the insert without chip breaker that produced continuous chips and higher surface roughness (Ra = 0.74–1.61 µm).

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