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Design of chip breaker and study on cutting performance in reaming 7050 aluminum alloy

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Abstract

Chip breaker is considered to be one of the most effective methods in chip control, which has been widely used in metal machining. Reaming is the final finishing operation in hole machining; smaller geometrical tolerance and higher surface quality should be achieved in reaming process. According to the characteristic of reaming operation, a smaller cutting allowance was required, thus inducing thin chips generated and hard to be broken, especially machining highly ductile materials, such as the 7050 aluminum alloy. In this study, the design of chip breakers on cutting edge of polycrystalline diamond (PCD) reamers was analyzed. Based on the characteristics of reamer and chip breaking conditions, theoretically chip breakage ranges for depth of chip breaker were deduced. According to theoretical ranges, two chip breaker reamers, with depths of 0.2mm and 0.4mm and a width of 0.5 mm, were designed and compared based on the chip breakability with a conventional non-chip breaker tool. The finite element method (FEM) analysis and reaming experiments were used to verify theoretical deduction. The results showed that chip breaking performances by FEM simulation and experimental research are in good agreement with predictions. Chip breakability of tool B (within theoretical range) has improved compared with the other tools. This study also provides a reference for the fabrication of chip breaker on reamers to improve chip breakability and surface quality.

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Data availability

All the data have been presented in the manuscript.

Code availability

Not applicable.

Abbreviations

L :

Width of cutting edge

k r :

Major cutting edge angle

ξ :

Chip compression ratio

L f :

Tool-chip contact length

H :

Depth of chip breaker

h ch :

Chip thickness

W e :

Width of chip breaker

r :

Radius of chip breaker

R d :

Radius of initial hole diameter

R T :

Radius of tool diameter

v c :

Cutting speed

a p :

Depth of cut

f :

Feed rate

R c :

The initial chip up-curl radius

R L :

The final chip up-curl radius

K r :

Ratio of RL to Rc

K R :

Ratio of Kr to Kr-1

ε :

The strain of chip material

ε B :

The ultimate tensile strain of chip material

k :

Contact coefficient

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Acknowledgements

The authors thank the Guohong tool system (Wuxi) Co., Ltd, for providing the testing conditions, etc.

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Authors and Affiliations

  1. School of Mechatronics Engineering and Automation, Shanghai University, Shanghai, 200444, China

    Zi Ye, Dejin Lv & Yongguo Wang

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  1. Zi Ye
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  2. Dejin Lv
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  3. Yongguo Wang
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Contributions

The first author, Z. Ye, was responsible for writing this article, established a theoretical model of chip breaker, and applied it on PCD reamers. She also established 3D-reaming simulation model and carried out reaming experiments. D. J. Lv is responsible for data processing and experimental research. She is also responsible for picture editing and language revision. The corresponding author, Y.G. Wang, is responsible for determining the overall logical structure of the paper and guiding the entire experiment.

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Correspondence to Yongguo Wang.

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Ye, Z., Lv, D. & Wang, Y. Design of chip breaker and study on cutting performance in reaming 7050 aluminum alloy. Int J Adv Manuf Technol 116, 159–173 (2021). https://doi.org/10.1007/s00170-021-07393-9

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