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Study on tool wear for efficient grooving blisk with disc milling cutter

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Abstract

Tool wear has an important influence on machining quality, cost, cutting force and heat. Grooving blisk with disc milling cutter is 3–4 times more efficient than plunge milling and side milling, but the tool wear is serious because of the large milling force and high milling temperature during the machining process. In the study, the damage and wear morphology of the tool was observed by focused ion/double beam system; the wear mechanism was studied by energy spectrum analysis; the tool life curve was drawn by the increase of flank wear. The experimental results show that the main wear and damage morphologies of disc milling cutter are chip sticking to the tool, chip accumulation, edge collapse, peeling, crack, plastic deformation and boundary wear; the main wear mechanism are abrasive wear, adhesive wear, oxidation wear and diffusion wear; the wear rate of the left blade is the fastest, followed by the right blade, and the wear rate of the middle blade is the slowest. These results can provide guidance for iimproving tool life, optimizing tool and mproving machining processes.

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Acknowledgments

This work was supported by the National Numerical Control Major Projects Foundation of China (Grant No. 2013ZX0400 1081); Hubei Superior and Distinctive Discipline Group of “Mechatronics and Automobiles”; Hubei Superior and Distinctive Discipline Group of “New Energy Vehicle and Smart Transportation”; Hubei Longzhong Laboratory, Xiangyang 441000, Hubei, China; Science and technology project of Xiangyang City (Grant No. 2021AAHO03594).

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Authors and Affiliations

  1. Key Laboratory of Aero-engine High Performance Manufacturing, Ministry of Industry and Information Technology, Northwestern Polytechnical University, Xi’an, 710072, China

    Qingsi Cheng, Changfeng Yao & Minchao Cui

  2. Hubei Chaozhuo Aviation Technology Co., Ltd., Xiangyang, 441000, China

    Qingsi Cheng & Guangping Li

  3. Hubei Key Laboratory of Power System Design and Test for Electrical Vehicle, Hubei University of Arts and Science, Xiangyang, 441053, China

    Song Wang, Hongmin Xin & Jian Zhang

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  1. Qingsi Cheng
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  2. Song Wang
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  3. Hongmin Xin
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  4. Jian Zhang
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  5. Changfeng Yao
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  6. Minchao Cui
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  7. Guangping Li
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Corresponding author

Correspondence to Hongmin Xin.

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Xin Hongmin is a Postdoctoral Fellow in Aerospace Manufacturing Engineering of Northwestern Polytechnical University of China. She received her doctorate in mechanical engineering from Northwestern Polytechnical University. Her research interests are numerical control intelligent equipment and process technology for aviation complex curved surface structures, Internet of Things and intelligent transportation technology.

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Cheng, Q., Wang, S., Xin, H. et al. Study on tool wear for efficient grooving blisk with disc milling cutter. J Mech Sci Technol 37, 5335–5348 (2023). https://doi.org/10.1007/s12206-023-0935-2

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  • DOI: https://doi.org/10.1007/s12206-023-0935-2

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