Tool Wear and Machined Surface Roughness during Wood Flour/Polyethylene Composite Peripheral Up-milling using Cemented Tungsten Carbide Tools

Abstract

The effect of sharpness angle on tool wear and the effect of tool wear on machined surface roughness were investigated in wood flour/polyethylene composite (WFPEC) peripheral up-milling using cemented tungsten carbide (TC) tools. It was shown that nose width and edge recession increased with increasing feeding length. During the milling process, the wear of the nose width was smallest for the tool with a sharpness angle of 45°, followed by tools with sharpness angles of 55° and 65°. The wear of edge recession was highest for the tool with a sharpness angle of 45°, followed by tools with sharpness angles of 55° and 65°. The nose width increased with increasing sharpness angle, the edge recession decreased with increasing sharpness angle, and the machined surface roughness increased with increasing sharpness angle after a feeding length of 40 m. The nose width had a positive effect on the machined surface roughness, and the machined surface roughness increased with increasing nose width. The edge recession had little effect on the machined surface roughness. The clearance face roughness of the worn tool increased with increasing sharpness angle. The analysis of the SEM micrographs and EDS of the clearance face of the worn tool showed that the wear mechanisms of the cemented tungsten carbide tool were oxidation and abrasion in the range tested during cutting. Thus, a slight wear of the edge recession is gained in exchange for a lower machined surface roughness by decreasing the sharpness angle.

Machinability of Stone—Plastic Materials During Diamond Planing

“…Cutting quality is the basic guarantee of production quality, which is generally evaluated by the mean peak-to-valley height and average deviation of surface roughness [21]. Wu et al studied the effect of cutting depth on cutting quality when turning a micro-prism array with diamond tools and showed that cutting depth affects surface defects; cutting depths greater than 4 µm further degraded the quality of the machined surface [22].…”

Wear of cemented tungsten carbide (WC) router cutters during oak wood milling

“…According to G. Ramasamy and J. Ratnasingam al., the wear of cutting edge increases with the increasing cutting length [2]. X. Guoa et al determined in their research that the wear of the cutting edge is the most intensive in the initial wear stage which converts to monotonic wear later [6].…”

“…More intensive wear of tools' cutting edge appear when tools are used to process wet wood or wood based materials [3,4]. During cutting thermal, electric, and chemical factors affects the wear of WC tools' blades [5][6][7][8][9][10][11]. The wear of cutting edge (change in the micro-geometry of the cutting edge) is the main factor that restricts the efficiency of tools [4,6,12].…”

“…During cutting thermal, electric, and chemical factors affects the wear of WC tools' blades [5][6][7][8][9][10][11]. The wear of cutting edge (change in the micro-geometry of the cutting edge) is the main factor that restricts the efficiency of tools [4,6,12]. According to the tests, the wear of the tool's cutting edge depends on the cutting length or processing duration, tool's material, cutting mode, and main characteristics of the processed solid wood or wood composites [3,4,13,14].…”

“…According to the tests, the wear of the tool's cutting edge depends on the cutting length or processing duration, tool's material, cutting mode, and main characteristics of the processed solid wood or wood composites [3,4,13,14]. The wear of the tool's cutting edge might be divided into three stages: initial, monotonic and emergency [5,6,13]. The wear of the cutting edge leads to continuous decreasing of quality of the processed surfaces [15][16][17].…”