Experimental study and simulation on the chip sticking–welding of the carbide cutter’s rake face

  • Jinguo Chen
  • Minli Zheng
  • Pengfei Li
  • Jingyang Feng
  • Yushuang Sun
Technical Paper
First Online:
Received:
Accepted:
  • 61 Downloads

Abstract

For the study of the tool-chip sticking–welding principle and welding layer formation conditions of the carbide cutter’s rake face, the actual conditions of sticking–welding occurrence during the cutting process were analyzed and the cutting test system which is equivalent to sticking–welding phenomenon was set up. Combined with the finite element simulation technology, sticking–welding phenomenon was analyzed. The effect of stress and temperature field with different cutting parameters on the occurrence of tool-chip sticking–welding and adhesion failure was revealed and adhesion failure location resulting from tool-chip sticking–welding was also obtained. Then aimed at the cutting temperature in the damaged area of the rake face, the mapping model was established using design-expert based on the response surface methodology. The trend of cutting temperature and the state of sticking–welding under the interaction between different parameters were obtained, which provided a theoretical basis for the selection of cutting parameters to avoid sticking–welding.

Keywords

Carbide cutter Stainless steel Interaction Response surface methodology Cutting temperature 
This is a preview of subscription content, log in to check access.

References

  1. 1.
    Li, L.: Research on tool-chip stick welding and stick welding surface dynamic characteristics in cutting 2.25Cr1Mo0.25V. Harbin Univ. Sci. Technol. 3, 13–14 (2015)Google Scholar
  2. 2.
    Zheng, M., Guo, J., Sun, S.: Characteristic of macroscopic mesoscopic diffusion wear of cutting tool in high speed turning of titanium alloys[J]. J. Shenyang Univ. Technol. 37(3), 304–311 (2015)Google Scholar
  3. 3.
    Zanger, F., Schulze, V.: Investigations on mechanisms of tool wear in machining of Ti–6Al–4V using FEM simulation. ProcediaCirp 8, 158–163 (2013)Google Scholar
  4. 4.
    Shashidhara, S., Liu, X., Zhu, W., et al.: Experimental investigation of the tool wear and tool life in micro hard milling. In: ASME 2013 International Mechanical Engineering Congress and Exposition. pp. V02AT02A073-V02AT02A073 (2013)Google Scholar
  5. 5.
    Park, K.H.: Tool wear analysis on multi-layered coated carbide tools in face milling of AISI 1045 steel. In: ASME 2010 International Manufacturing Science and Engineering Conference. American Society of Mechanical Engineers, pp. 363–370 (2010)Google Scholar
  6. 6.
    Wang, H., Dong, Z., Kang, R., et al.: Experimental investigation of cutting force and cutting temperature on helical milling of titanium alloy. Aeronaut. Manuf. Technol. 9, 91–97 (2016)Google Scholar
  7. 7.
    Sun, Y., Sun, J., Li, J., et al.: An experimental investigation of the influence of cutting parameters on cutting temperature in milling Ti6Al4V by applying semi-artificial thermocouple. Int. J. Adv. Manuf. Technol. 70(5), 765–773 (2014)CrossRefGoogle Scholar
  8. 8.
    Kovac, P., Rodic, D., Pucovsky, V., et al.: Multi-output fuzzy inference system for modeling cutting temperature and tool life in face milling. J. Mech. Sci. Technol. 28(10), 4247–4256 (2014)CrossRefGoogle Scholar
  9. 9.
    Shan, C., Wang, X., Yang, X., et al.: Prediction of cutting forces in ball-end milling of 2.5D C/C composites. Chin. J. Aeronaut. 29(3), 824–830 (2016)CrossRefGoogle Scholar
  10. 10.
    Paris, H., Peigné, G.: Influence of the cutting tool geometrical defects on the dynamic behaviour of machining. Int. J. Interact. Des. Manuf. (IJIDeM) 1(1), 41–49 (2007)CrossRefGoogle Scholar
  11. 11.
    Batista, M., Salguero, J., Gómez, A., et al.: Identification, analysis and evolution of the mechanisms of wear for secondary adhesion for dry turning processes of Al–Cu alloys. Adv. Mater. Res. 107(107), 141–146 (2010)CrossRefGoogle Scholar
  12. 12.
    Chinchanikar, S., Choudhury, S.K.: Effect of work material hardness and cutting parameters on performance of coated carbide tool when turning hardened steel: An optimization approach. Measurement 46, 1572–1584 (2013)CrossRefGoogle Scholar
  13. 13.
    Yaonan, C., Xianli, L., Zhenjia, L., et al.: Adhering failure of the tool-chip in the process of extremely heavy cutting. J. Mech. Eng. 48(19), 169–176 (2012)CrossRefGoogle Scholar
  14. 14.
    Ezilarasan, C., Kumar, V.S.S., Velayudham, A.: Theoretical predictions and experimental validations on machining the Nimonic C-263 super alloy. Simul. Model. Pract. Theory 40(1), 192–207 (2014)CrossRefGoogle Scholar
  15. 15.
    Axinte, D.A., Dewes, R.C.: Surface integrity of hot work tool steel after high speed milling-experimental data and empirical models[J]. J. Mater. Process. Technol. 127(3), 325–335 (2002)CrossRefGoogle Scholar
  16. 16.
    Asad, M., Mabrouki, T., Rigal, J.F.: On the tool vibration effects during down-cut peripheral milling process. Int. J. Interact. Des. Manuf. (IJIDeM) 4(4), 215–225 (2010)CrossRefGoogle Scholar
  17. 17.
    Wan, L., Wang, D.Z.: Numerical analysis of the formation of the dead metal zone with different tools in orthogonal cutting. Simul. Model. Pract. Theory 56, 1–15 (2015)CrossRefGoogle Scholar
  18. 18.
    Hu, Y.J., Wang, Y., Wang, Z.L.: Temperature field numerical analysis of machining process based on the finite element analysis. Key Eng. Mater. 621, 611–616 (2014)CrossRefGoogle Scholar
  19. 19.
    Li, Z.: Research on cutting force and thermal characteristics and sticking failure mechanism of carbide tool in turning high-strength steel. Harbin Univ. Sci. Technol. 3, 72–73 (2013)Google Scholar

Copyright information

© Springer-Verlag France 2017

Authors and Affiliations

  • Jinguo Chen
    • 1
    • 2
  • Minli Zheng
    • 1
  • Pengfei Li
    • 1
  • Jingyang Feng
    • 1
  • Yushuang Sun
    • 1
  1. 1.College of Mechanical and Power EngineeringHarbin University of Science and TechnologyHarbinChina
  2. 2.School of Electrical and Mechanical EngineeringPutian UniversityPutianChina

Personalised recommendations