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Analysis of PCBN tool failure mechanisms in face milling of hardened steel using damage equivalent stress

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Abstract

An attempt was made in the present study to apply damage mechanics to investigate the polycrystalline cubic boron nitride (PCBN) tool failure mechanisms in face milling of hardened steel. Experimental phenomenon relating to damage accumulation was found by means of analyzing the tool wear evolution and macroscale failure of the cutting tool. Damage equivalent stress was used as an indicator to reveal the tool failure mechanisms under different cutting conditions. Because of the larger value of damage equivalent stress, there was greater likelihood of tool fracture in down milling than that in up milling. Deflection of the shear angle changed the tool stress component and distribution substantially in up milling, leading to the emergence of the peak value of damage equivalent stress in spite of lower values of cutting force and tool temperature. Calculated damage equivalent stress and tool lives obtained in milling tests were compared and analyzed. It was found that damage equivalent stress can be used as an effective tool to analyze the tool failure mechanisms and assess the optimum cutting condition.

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Authors and Affiliations

  1. School of Mechanical and Power Engineering, Henan Polytechnic University, Jiaozuo, 454003, People’s Republic of China

    Xiaobin Cui & Yanyan Yan

  2. School of Energy Science and Engineering, Henan Polytechnic University, Jiaozuo, 454003, People’s Republic of China

    Jingxia Guo

  3. Key Laboratory of High Efficiency and Clean Mechanical Manufacture of MOE, School of Mechanical Engineering, Shandong University, Jinan, 250061, People’s Republic of China

    Jun Zhao

Authors
  1. Xiaobin Cui
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  2. Jingxia Guo
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  3. Jun Zhao
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  4. Yanyan Yan
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Correspondence to Xiaobin Cui.

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Cui, X., Guo, J., Zhao, J. et al. Analysis of PCBN tool failure mechanisms in face milling of hardened steel using damage equivalent stress. Int J Adv Manuf Technol 80, 1985–1994 (2015). https://doi.org/10.1007/s00170-015-7175-2

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  • DOI: https://doi.org/10.1007/s00170-015-7175-2

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