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Cross-scale identification method for friction damage on the tool flank of high-feed milling cutter

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Abstract

Due to high cutting speed and intermittent impact load, there exists significant friction and cutting vibration in milling process, which would lead to the mesoscopic friction damages. The friction damages and wear state thus become difficult to predict. In this work, the variation of instantaneous mechanical behavior of the milling cutter flank under vibration was studied. The structural deformation and friction damages of milling cutter flank in macro/mesoscopes were analyzed by conducting both thermal stress coupling field and molecular dynamic analysis. The multi-scale characterization method of instantaneous friction damage on cutter flank was proposed. The super-cell model of the tool-workpiece on the tool flank was developed. The variation of super-cell configuration was obtained. The nucleation and propagation of friction damages were identified; the evolution of mesoscopic friction damages on tool flank were revealed. The mesoscopic friction damage evolution of different positions on tool flank was researched; the coupling and competition mechanisms between the nucleation and propagation process of friction damages were unveiled. The cross-scale identification method of the friction damages of tool flank was validated by experiments.

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Data availability

The datasets generated during and/or analyzed during the current study are available from the corresponding author on reasonable request.

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Funding

This research was funded by the Natural Science Foundation of Heilongjiang Province of China, ZD2020E008; the National Natural Science Foundation of China, 52105440; and the National Natural Science Foundation of China, 51875145; Opening Project of the Key Laboratory of Advanced Processing Technology and Intelligent Manufacturing (Heilongjiang Province), KFKT202206.

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Authors and Affiliations

  1. Key Laboratory of Advanced Processing Technology and Intelligent Manufacturing (Heilongjiang Province), Harbin University of Science and Technology, Harbin, 150080, People’s Republic of China

    Bin Jiang, Feifei Li, Peiyi Zhao, Lili Fan & Shuling Sun

Authors
  1. Bin Jiang
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  2. Feifei Li
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  3. Peiyi Zhao
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  4. Lili Fan
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  5. Shuling Sun
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Contributions

All authors contributed to the study conception and design. Conceptualization, Bin Jiang and Feifei Li; methodology, Peiyi Zhao and Bin Jiang; software, Feifei Li and Lili Fan; validation, Shuling Sun and Feifei Li; investigation, Lili Fan and Shuling Sun; data curation, Shuling Sun and Feifei Li; writing—original draft preparation, Feifei Li; writing—review and editing, Feifei Li and Peiyi Zhao; supervision, Bin Jiang and Peiyi Zhao; project administration, Bin Jiang and Peiyi Zhao; funding acquisition, Bin Jiang and Peiyi Zhao. All authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Peiyi Zhao.

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Jiang, B., Li, F., Zhao, P. et al. Cross-scale identification method for friction damage on the tool flank of high-feed milling cutter. Int J Adv Manuf Technol 131, 3665–3694 (2024). https://doi.org/10.1007/s00170-024-13122-9

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