Determination of friction in metal cutting with tool wear and flank face effects

Abstract This paper studies friction for oblique cutting when using turning chamfered Si 3 N 4 ceramic tools with a large negative rake angle. In particular, friction on the flank face is incorporated in the tribological balance. The values of force components recorded during tool wear tests at different cutting speeds were used as input data. The usual force components were transformed into the tool-in-use coordinate system to enable computing the friction and normal forces acting on the rake and flank faces and finally the relevant friction coefficients. It was revealed that both friction coefficients change substantially during tool wear progression and differ from those determined for orthogonal friction model. The new friction model was tested for the machining of spheroidal cast iron (SCI) using coated nitride ceramic inserts and additionally validated by cylinder-on-disc tribo-testing.

[1]  W. Grzesik,et al.  Experimental investigation of the influence of adhesion on the frictional conditions in the cutting process , 1999 .

[2]  Yusuf Altintas,et al.  Mechanics of machining with chamfered tools , 2000 .

[3]  Wit Grzesik,et al.  Friction and wear testing of multilayer coatings on carbide substrates for dry machining applications , 2002 .

[4]  Abdelwaheb Dogui,et al.  Identification of a friction model at tool/chip/workpiece interfaces in dry machining of AISI4142 treated steels , 2009 .

[5]  Tuğrul Özel,et al.  The influence of friction models on finite element simulations of machining , 2006 .

[6]  Wit Grzesik,et al.  Friction quantification in the oblique cutting with CBN chamfered tools , 2013 .

[7]  Wit Grzesik,et al.  The influence of thin hard coatings on frictional behaviour in the orthogonal cutting process , 2000 .

[8]  Yusuf Altintas,et al.  Generalized dynamic model of metal cutting operations , 2013 .

[9]  J. Rech,et al.  Machining of Nodular Cast Iron (PF-NCI) Using CBN Tools , 2012 .

[10]  Wit Grzesik,et al.  Documentation of tool wear progress in the machining of nodular ductile iron with silicon nitride-based ceramic tools , 2011 .

[11]  Wit Grzesik,et al.  A new mechanistic friction model for the oblique cutting with tool wear effect , 2013 .

[12]  T. Childs,et al.  Friction modelling in metal cutting , 2006 .

[13]  Wit Grzesik.  The mechanics of continuous chip formation in oblique cutting with single-edged tool — Part I. Theory , 1990 .

[14]  Mats Andersson,et al.  Effect of chamfer angle on wear of PCBN cutting tool , 2003 .

[15]  M. C. Shaw.  Metal Cutting Principles , 1960 .

[16]  C. A. van Luttervelt,et al.  An Investigation of the Thermal Effects in Orthogonal Cutting Associated with Multilayer Coatings , 2001 .

[17]  Wit Grzesik,et al.  The mechanics of continuous chip formation in oblique cutting with single-edged tool—part II. Experimental verification of the theory , 1990 .

[18]  I. Hutchings.  Tribology: Friction and Wear of Engineering Materials , 1992 .

[19]  Ranga Komanduri,et al.  The significance of normal rake in oblique machining , 2004 .

[20]  Pedro J. Arrazola,et al.  A new approach for the friction identification during machining through the use of finite element modeling , 2008 .