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Tool failure mechanisms and cutting performance analysis during high-feed milling of 508-III steel

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Abstract

508-III steel has become one of the most viable materials for heavy nuclear reactor pressure vessels due to its excellent strength and fracture toughness. However, the poor machinability of 508-III steel requires the tool to withstand extremely high mechanical stress, thermal stress, and shock during the cutting process, thereby accelerating tool failure and affecting machining efficiency. High-feed milling (HFM) is a novel rough machining technology that ensures machining efficiency and prolongs tool life. This paper aims to reveal tool failure mechanisms during HFM of 508-III steel and to indirectly evaluate the cutting performance of the HFM cutter in the context of cutting vibration and chip morphology. Dry milling experiments of 508-III steel were carried out using an HFM cutter with arc-shaped bottom edges. Experimental results show adhesion, oxidation, and diffusion are the primary tool wear mechanisms. The wear levels between each insert present significant differences, which can be explained by cutting-edge position deviations and unexpected tool movements. With the continuous accumulation of tool wear, the insert with the weakest cutting edge strength is broken, which can be attributed to the crack propagation near the cutting edge, hard spots, and the shedding of adhesive materials. When the feed per tooth is 0.8~1.0 mm, the whole milling process shows good stability, especially in the spindle direction. The chip morphology and color variations are closely related to tool wear, which can provide an essential basis for tool failure prediction.

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Funding

This work is financially supported by the National Key Research and Development Program of China (Grant No. 2019YFB1704800). The authors would like to thank China First Heavy Industries (CFHI) and CERATIZIT tool company for providing the workpiece material and technical support, respectively.

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Authors and Affiliations

  1. Key Laboratory of Advanced Manufacturing and Intelligent Technology, Ministry of Education, Harbin University of Science and Technology, Harbin, 150080, China

    Xuebing Li, Xianli Liu & Caixu Yue

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  1. Xuebing Li
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Contributions

Xuebing Li: methodology, investigation, data curation, writing — original draft, writing — review and editing, visualization; experiments, data curation; Xianli Liu: project administration, investigation, conceptualization, supervision; Caixu Yue: writing — review and editing, supervision, validation.

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Correspondence to Xianli Liu.

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Li, X., Liu, X. & Yue, C. Tool failure mechanisms and cutting performance analysis during high-feed milling of 508-III steel. Int J Adv Manuf Technol 128, 3921–3936 (2023). https://doi.org/10.1007/s00170-023-12045-1

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  • DOI: https://doi.org/10.1007/s00170-023-12045-1

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