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Experimental study on coupling characteristics of cutting temperature rise and cutting vibration under different tool wear states

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Abstract

The thermo-mechanical-vibration coupling characteristics of the cutting system has always been an important research topic in the field of machining, and the material, states, and performance of cutting tools can directly affect these coupling characteristics. In this paper, a synchronous testing system is built to collect the cutting temperature and cutting vibration near the tip of three tools with different wear states: D1 (new blade), D2 (moderately worn blade), and D3 (severely worn blade). Based on the test data and the gray correlation theory, the coupling characteristics of cutting temperature rise and cutting vibration under different tool wear states are analyzed. Based on the experimental data and least square method, (1) the regression model of cutting temperature rise about cutting vibration and cutting parameters are established, (2) the regression model of cutting vibration about cutting temperature rise and cutting parameters are established. The undetermined parameters and correlation coefficients are obtained by MATLAB software programming. The research results show that for tools D1 and D2, the coupling of cutting temperature rise and cutting vibration is a one-way coupling, that is, cutting vibration and cutting parameters significantly affects cutting temperature, but cutting temperature rise and cutting parameters has little effect on cutting vibration, while for tool D3, the coupling of cutting temperature rise and cutting vibration is a bi-directional coupling.

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Data availability

The data in this paper are all obtained from experiments. All data generated during this study are included in this manuscript.

Abbreviations

n :

The spindle speed

v :

The cutting speed

v f :

The feed speed

a p :

The cutting depth

\( \Delta \overline{T} \) :

The measured mean temperature rise

\( \Delta {\tilde{T}}_a \) (axial):

The predicted mean temperature rise by three-way vibration and cutting parameters

\( \Delta {\tilde{T}}_r \) (radial):

The predicted mean temperature rise by three-way vibration and cutting parameters

\( \Delta {\tilde{T}}_t \) (tangential):

The predicted mean temperature rise by three-way vibration and cutting parameters

a a (axial):

The three-way vibration acceleration

a r (radial):

The three-way vibration acceleration

a t (tangential):

The three-way vibration acceleration

P :

The probability value of zero correlation

\( {\overline{a}}_{\mathrm{RMS}\hbox{-} \mathrm{a}} \) (axial):

The measured root-mean-square value of three-way cutting vibration acceleration

\( {\overline{a}}_{\mathrm{RMS}\hbox{-} \mathrm{r}} \) (radial):

The measured root-mean-square value of three-way cutting vibration acceleration

\( {\overline{a}}_{\mathrm{RMS}\hbox{-} \mathrm{t}} \) (tangential):

The measured root-mean-square value of three-way cutting vibration acceleration \( {\tilde{a}}_{\mathrm{RMS}\hbox{-} \mathrm{a}} \) (axial)

The predicted root-mean-square value of three-way cutting vibration acceleration

\( {\tilde{a}}_{\mathrm{RMS}\hbox{-} \mathrm{r}} \) (radial):

The measured root-mean-square value of three-way cutting vibration acceleration

\( {\tilde{a}}_{\mathrm{RMS}\hbox{-} \mathrm{t}} \) (tangential):

The measured root-mean-square value of three-way cutting vibration acceleration

D1:

The new blade

D2:

The moderately worn blade

D3:

The severely worn blade

R D1 R D2 R D3 :

The gray correlation coefficients for tool D1, D2, D3

C, x, y, z, w :

The undetermined coefficients

R :

The correlation coefficient

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Funding

This work was supported by the Postgraduate Research and Practice Innovation Program of Jiangsu Province (KYCX20_2331), Joint scientific research project of Sino foreign cooperative education platform in Jiangsu Province, the Science and Technology Plan Project of Xuzhou City (KC20188), and Undergraduate Innovation Training Program (202010320033Z).

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Authors and Affiliations

  1. School of Mechanical and Electrical Engineering, Jiangsu Normal University, Xuzhou, 221116, Jiangsu, China

    Songyuan Li

  2. JSNU-SPBPU Institute of Engineering, Jiangsu Normal University, Xuzhou, 221116, Jiangsu, China

    Shuncai Li & Yuting Hu

  3. Higher School of applied physics and space technologies, Petersburg Polytechnic University, Saint-Petersburg, 1952151, Russia

    Eugene Popov

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  1. Songyuan Li
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  2. Shuncai Li
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  4. Eugene Popov
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Contributions

Songyuan Li:Write original manuscript and translate;

Shuncai Li:Revise the paper and verify the results;

Yuting Hu:Experiment, data collection, verifying;

Eugene Popov:Test and data processing.

All authors of this paper have read and approved the final version submitted.

Corresponding author

Correspondence to Shuncai Li.

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My research does not involve ethical issues.

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My research does not involve ethical issues, it only involves aluminum alloy and other materials processing problems and requires workers to process workpieces.

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Li, S., Li, S., Hu, Y. et al. Experimental study on coupling characteristics of cutting temperature rise and cutting vibration under different tool wear states. Int J Adv Manuf Technol 118, 907–919 (2022). https://doi.org/10.1007/s00170-021-07948-w

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  • DOI: https://doi.org/10.1007/s00170-021-07948-w

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