Formation characteristics of the chip and damage equivalent stress of the cutting tool in high-speed intermittent cutting

For the purpose of revealing the formation characteristics of the chip and analyzing damage equivalent stress of the cutting tool in high-speed intermittent cutting, cutting tests, and finite element simulation were performed in the present work. Characteristics of chip morphologies acquired in cutting tests were analyzed and compared for different cutting conditions. The effects of cutting parameters on force, temperature, and stress on the shear plane were investigated. On the basis of the concept of damage equivalent stress, the initial damage of the cutting tool and the tool stress were integrated and the influences of cutting parameters on damage equivalent stress were studied. The correlations between damage equivalent stress of the cutting tool and chip formation were analyzed. Analysis results indicated that there existed strong correlations between the evolution of damage equivalent stress of the cutting tool and the chip formation process. Relatively low damage equivalent stress and relatively long tool life appeared at the same time when small values of cutting speed and feed rate were used.

[1]  S. Nemat-Nasser,et al.  Brittle failure in compression: splitting faulting and brittle-ductile transition , 1986, Philosophical Transactions of the Royal Society of London. Series A, Mathematical and Physical Sciences.

[2]  Jun Zhao,et al.  The effects of cutting parameters on tool life and wear mechanisms of CBN tool in high-speed face milling of hardened steel , 2013 .

[3]  Sia Nemat-Nasser,et al.  A Microcrack Model of Dilatancy in Brittle Materials , 1988 .

[4]  Liu Zhanqiang,et al.  Characteristics of chip evolution with elevating cutting speed from low to very high , 2012 .

[5]  C. K. Toh,et al.  Cutter path orientations when high-speed finish milling inclined hardened steel , 2006 .

[6]  W. Ma,et al.  Cutting AISI 1045 steel at very high speeds , 2012 .

[7]  M. C. Shaw,et al.  Mechanics of Saw-Tooth Chip Formation in Metal Cutting , 1999 .

[8]  Jun Zhao,et al.  Cutting performance of coated carbide tools in high-speed face milling of AISI H13 hardened steel , 2014 .

[9]  Yi Wan,et al.  Wear patterns and mechanisms of cutting tools in high-speed face milling , 2002 .

[10]  J. Lemaître,et al.  Engineering Damage Mechanics: Ductile, Creep, Fatigue and Brittle Failures , 2005 .

[11]  John M Kemeny,et al.  A MODEL FOR NON-LINEAR ROCK DEFORMATION UNDER COMPRESSION DUE TO SUB- CRITICAL CRACK GROWTH , 1991 .

[12]  Jun Zhao,et al.  Performance of graded nano-composite ceramic tools in ultra-high-speed milling of Inconel 718 , 2013 .

[13]  Jun Zhao,et al.  Fabrication and cutting performance of an Al2O3-(W, Ti)C functionally gradient ceramic tools , 2006 .

[14]  Yuebin Guo,et al.  A FEM study on mechanisms of discontinuous chip formation in hard machining , 2004 .

[15]  U. Umer.  High Speed Turning of H-13 Tool Steel Using Ceramics and PCBN , 2012, Journal of Materials Engineering and Performance.

[16]  Song Zhang,et al.  Tool life and cutting forces in end milling Inconel 718 under dry and minimum quantity cooling lubrication cutting conditions , 2012 .

[17]  M. C. Shaw,et al.  Chip Formation in the Machining of Hardened Steel , 1993 .

[18]  F. Jiao,et al.  Chip formation and its effects on cutting force, tool temperature, tool stress, and cutting edge wear in high- and ultra-high-speed milling , 2016 .

[19]  Jun Zhao,et al.  Tool wear in high-speed face milling of AISI H13 steel , 2012 .

[20]  Dong Wang,et al.  Performance optimization for cemented carbide tool in high-speed milling of hardened steel with initial microstructure considered , 2016 .

[21]  A. Molinari,et al.  Adiabatic shear banding in high speed machining of Ti-6Al-4V: experiments and modeling , 2002 .