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A methodology to predict thermal crack initiation region of tool for high-speed milling compacted graphite iron based on three-dimensional transient thermal stress field model

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Abstract

Compacted graphite iron (CGI) plays a key role in engine reliability and achieving high emission standards. However, it is a difficult-to-machine material. The main reason for tool breakage in high-speed milling compacted graphite iron (CGI) is related to the thermal crack of tool caused by thermal load. The three-dimensional transient thermal stress field model of tool for high-speed milling CGI was established for the first time, and the thermal crack initiation region of tool during high-speed milling CGI was predicted based on this model; it was predicted that the areas prone to initiate thermal cracks were 0 ≤ X ≤ 0.09 mm, 0 ≤ Y ≤ 0.27 mm, and 0.25 ≤ Z ≤ 2.05 mm. The temperature variation of cemented carbide tool in symmetrical end-face milling was simulated by using high-power laser simulation experiment. The heating time and cooling time of laser heating tool were determined according to the actual cutting process, which were the same as the cutting time and non-cutting time in actual milling, and the number of thermal shocks during heating was the same as that of tool failure in actual milling. The macro lens of the infrared thermal imager was used to measure the temperature, and the temperature required for the experiment was obtained by adjusting the laser power. The method of predicting the thermal crack initiation region of tool for high-speed milling CGI has important theoretical significance for the directional precise design of tools efficiently.

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Funding

This work was supported by National Natural Science Foundation of China [52075300, 52275464]; Scientific Research Project for National High-level Innovative Talents of Hebei Province Full-time Introduction [2021HBQZYCXY004]; Natural Science Foundation of Shandong Province [ZR2022ZD08].

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Authors and Affiliations

  1. Center for Advanced Jet Engineering Technology (CaJET), School of Mechanical Engineering, Shandong University, Jingshi Road 17923, Jinan, 250061, People’s Republic of China

    Limei Wang, Hanlian Liu, Yulan Yuan, Peng Yao, Jun Huang & Quanquan Han

  2. Key Laboratory of High-Efficiencyfficiency and Clean Mechanical Manufacture (Shandong University), Ministry of Education, Beijing, People’s Republic of China

    Limei Wang, Hanlian Liu, Yulan Yuan, Peng Yao, Jun Huang & Quanquan Han

  3. School of Mechanical Engineering, Yanshan University, Qinhuangdao, 066004, People’s Republic of China

    Chuanzhen Huang

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  1. Limei Wang
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  2. Hanlian Liu
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  3. Chuanzhen Huang
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  4. Yulan Yuan
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Contributions

Limei Wang: conceptualization, methodology, investigation, formal analysis, writing—original draft, writing—review and editing. Hanlian Liu: methodology, investigation, formal analysis, supervision, writing—review and editing. Chuanzhen Huang: formal analysis, supervision, writing—review and editing. Yulan Yuan: investigation, writing—review and editing. Yao Peng: formal analysis, supervision. Jun Huang: formal analysis, writing—review and editing. Quanquan Han: formal analysis.

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Correspondence to Hanlian Liu or Chuanzhen Huang.

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Wang, L., Liu, H., Huang, C. et al. A methodology to predict thermal crack initiation region of tool for high-speed milling compacted graphite iron based on three-dimensional transient thermal stress field model. Int J Adv Manuf Technol 125, 2065–2075 (2023). https://doi.org/10.1007/s00170-023-10832-4

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