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Effects of relative tool sharpness on surface generation mechanism of precision turning of electroless nickel-phosphorus coating

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Abstract

Relative tool sharpness (RTS) is identified as the ratio of undeformed chip thickness to tool cutting edge radius. This paper studies the effects of RTS on the surface generation mechanism of precision turning of electroless nickel-phosphorus (Ni-P) coating. An R-shaped tungsten carbide (WC) tool was adopted for the face turning experiment. The cutting edge radius was 1.84 μm measured by a laser scanning confocal microscope (LSCM). The chip formation behavior, cutting forces and surface morphology were investigated under different RTS values. Results showed that the chip changes from continuous to discontinuous as RTS decreases from 0.54 to 0.27, indicating the transition of the material removal mechanism. The periodical fluctuations with small amplitudes on the machined surface are associated with the high-frequency tool-tip vibration. The low-frequency fluctuations of the cutting forces are related to the material swelling and recovery. The optimal machined surface roughness was obtained at the RTS of 0.38.

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Abbreviations

a :

Slope of the line

cw :

Theoretical chip width

D :

Depth of cut

f :

Feed rate

F :

Resultant force of Fz and Fy

F x :

Feed force

F y :

Thrust force

F z :

Tangential force

r :

Cutting edge radius

R :

Tool nose radius

s :

Cutting speed

Sa :

Surface roughness

t :

Chip thickness

T :

Undeformed chip thickness

w :

Half-width of the engaged tool

x m :

Abscissa of point m

x n :

Abscissa of point n

y m :

Ordinate of point m

y n :

Ordinate of point n

δ :

Difference between Fz and Fy

φ :

Angle between F and the cutting direction

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Acknowledgments

This work was supported by the National Basic Research Program of China (grant number 2015CB059900), the National Natural Science Foundation of China (grant numbers 51775046, 51875043, and 52005040), Beijing Municipal Natural Science Foundation (grant number JQ20014) and China Postdoctoral Science Foundation (grant number 2019 M660480). Qian Yu acknowledges the financial support from China Scholarship Council (CSC) for his visiting research in Japan.

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Authors and Affiliations

  1. Key Laboratory of Fundamental Science for Advanced Machining, Beijing Institute of Technology, Beijing, 100081, China

    Qian Yu, Tianfeng Zhou, Yupeng He, Peng Liu & Xibin Wang

  2. Department of Mechanical Engineering, Faculty of Science and Technology, Keio University, Yokohama, 2238522, Japan

    Qian Yu & Jiwang Yan

  3. Beijing Institute of Technology Chongqing Innovation Center, Chongqing, 401120, China

    Tianfeng Zhou, Peng Liu & Xibin Wang

Authors
  1. Qian Yu
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  2. Tianfeng Zhou
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  3. Yupeng He
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  4. Peng Liu
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  5. Xibin Wang
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  6. Jiwang Yan
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Corresponding author

Correspondence to Tianfeng Zhou.

Additional information

Qian Yu is currently a Ph.D. candidate at Key Laboratory of Fundamental Science for Advanced Machining, Beijing Institute of Technology, Beijing, China. He received his Bachelor’s degree in School of Mechanical Engineering in Beijing Institute of Technology, Beijing, China, in 2015. He studied in Department of Mechanical Engineering in Keio University, Yokohama, Japan, from 2018 to 2019. His research interests include ultra-precision machining, micro- and nano-manufacturing.

Tianfeng Zhou is currently a Professor and a Ph.D. candidate supervisor at Key Laboratory of Fundamental Science for Advanced Machining, Beijing Institute of Technology, Beijing, China. He received his Ph.D. degree in Tohoku University, Japan, in 2009. He worked as an Assistant Professor in Tohoku University, Japan, from 2010 to 2012. His main research interests include extreme manufacturing, precision glass molding, mold material development, optical engineering, micro- and nano-manufacturing.

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Yu, Q., Zhou, T., He, Y. et al. Effects of relative tool sharpness on surface generation mechanism of precision turning of electroless nickel-phosphorus coating. J Mech Sci Technol 35, 3113–3121 (2021). https://doi.org/10.1007/s12206-021-0633-x

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  • DOI: https://doi.org/10.1007/s12206-021-0633-x

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