On the mechanism of three-body adhesive wear in turning

The tool geometry is generally of great significance in metal cutting performance. The response surface method was used to optimize chamfer geometry to achieve reliable and minimum tool wear in slot milling. Models were developed for edge chipping, rake wear, and flank wear. The adequacy of the models was verified using analysis of variance at a 95% confidence level. Each response was optimized individually, and the multiple responses were optimized simultaneously using the desirability function approach. The Monte Carlo simulation method was applied to tolerance analysis. All milling tests were conducted at dry conditions; the chamfer width and the chamfer angle varied between 0.1 and 0.3 mm, and 10 and 30°, respectively. Optimal chamfer geometry for minimizing chipping and rake wear was small chamfer width and chamfer angle. The flank wear reached the minimum value for the tool with 0.18 mm chamfer width and 10° chamfer angle. The obtained composite model predicted good edge strength and minimum overall wear when the chamfer was 0.1 mm wide at a 10° angle. Thermal cracks were observed on the tools. They were small on the edges with the finest and least negative chamfer but were more significant on the more negative and greater chamfer. A great chamfer width and chamfer angle also resulted in insufficient chip evacuation. The results show how the edge geometry affects the tool’s reliability and wear and may help manufacturers minimize tool cost and downtime.

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“…Abrasive wear [21] and adhesive wear [20] are the two primary mechanisms involved in the deterioration of the rake.…”

Section: Rake Wearmentioning

confidence: 99%

Effect of chamfer width and chamfer angle on tool wear in slot milling

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Svenningsson²

2022

Int J Adv Manuf Technol

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Exploring the mechanics of adhesion in metal cutting

Svenningsson

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2023

Int J Adv Manuf Technol

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The deterioration of the cutting edge during machining influences production cost and productivity. The adhesion is one of the main wear mechanisms. This study delves into the adhesive mechanism in the context of turning, milling, and drilling, focusing on three different cutting materials: 34CrNiMo6, 1.437 stainless steel, and ductile iron. Building upon previous research on the adhesive process in turning, a dynamic model was developed to understand the mechanism further. The results showed that adhesion is a general phenomenon occurring in all tested work materials, but with varying intensity levels. Intermittent cuts did not greatly impact the adhesive mechanism, and cutting data, coolant, and chip breaking also showed little effect. However, the presence of graphite in ductile iron temporarily inhibited adhesion. The source of the adhesive sound was found to be the pivoting movement of the chip as it binds and rips off the cutting tool, leading to a frequency shift upon detachment. The adhesive wear was found to be a thermal mechanism, where chemical reactions between the SiO2 in the work material with the cutting tool caused thermal cracks and low-frequency fatigue.

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Variation of Cutting Forces with Different Cutting Parameters and Tool Wear during Turning of 9442-Nickel-Aluminum Bronze

Zou,

Lai,

et al. 2024

J. of Materi Eng and Perform

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On the mechanism of three-body adhesive wear in turning

Cited by 7 publications

References 19 publications

Effect of chamfer width and chamfer angle on tool wear in slot milling

Effect of chamfer width and chamfer angle on tool wear in slot milling

Exploring the mechanics of adhesion in metal cutting

Variation of Cutting Forces with Different Cutting Parameters and Tool Wear during Turning of 9442-Nickel-Aluminum Bronze

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