On the Development of a Chip Breaker in a Metal-Matrix Polycrystalline Diamond Insert: Finite Element Based Design With ns-Laser Ablation and Machining Verification

Abstract

This paper reports the development of an original design of chip breaker in a metal-matrix polycrystalline diamond (MMPCD) insert brazed into a milling tool. The research entailed finite element (FE) design, laser simulation, laser fabrication, and machining tests. FE analysis was performed to evaluate the effectiveness of different designs of chip breaker, under specified conditions when milling aluminum alloy (Al A356). Then, the ablation performance of an MMPCD workpiece was characterized by ablating single trenches under different conditions. The profiles of the generated trenches were analyzed and fed into a simulation tool to examine the resultant thickness of ablated layers for different process conditions, and to predict the obtainable shape when ablating multilayers. Next, the geometry of the designated chip breaker was sliced into a number of layers to be ablated sequentially. Different ablation scenarios were experimentally investigated to identify the optimum processing conditions. The results showed that an ns laser utilized in a controllable manner successfully produced the necessary three-dimensional feature of an intricate chip breaker with high surface quality (Ra in the submicron range), tight dimensional accuracy (maximum dimensional error was less than 4%), and in an acceptable processing time (≈51 s). Finally, two different inserts brazed in milling tools, with and without the chip breaker, were tested in real milling trials. Superior performance of the insert with chip breaker was demonstrated by the curled chips formed and the significant reduction of obtained surface roughness compared to the surface produced by the insert without chip breaker.

Principles and Characteristics of Different EDM Processes in Machining Tool and Die Steels

“…Most of these materials are usually difficult to cut by conventional manufacturing processes [3][4][5][6][7]. The unique characteristics of these hard-to-cut materials increase their applications, which further drive manufacturers to explore new machining processes with reasonable cost and high precision [8,9]. Therefore, it is important to have in-depth knowledge of this subject and, hence, the aim of this research paper is to provide comprehensive information and details of this process.…”

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

“…Sreekala and Sreekala [36] chose a curved groove geometry as the basic design for a chip breaker. This geometry and the nomenclature were followed by other researchers [26,36]. It is expected that including backwall height to the chip breaker geometry would significantly restrict the chip breaker design, especially the radius of curvature.…”

“…However, to the best of the authors' knowledge, this is not the case for polycrystalline diamond (PCD) tools, where there is a gap in the market to offer reliable PCD inserts with chip breakers [25]. Due to its high hardness and high abrasive resistance, PCD inserts are widely used for the high-quality machining of non-ferrous metals such as aluminum alloys [26,27]. Given that aluminum alloys are ductile materials, the machining processes of such materials are associated with the generation of continuous chips that require dependable chip control.…”

From macro to micro, evolution of surface structures on cutting tools: a review

“…High energy beam machining is another option to produce macro surface structures on tools with high precision and acceptable efficiency. Gonzalo [17] and Elkaseer et al [18] applied laser ablation to make 3D chip-breakers on PCD insert and blades of milling tool. In addition, the electrodischarge machining (EDM) is also turned out feasible for making chip-breaker [19].…”