Tool wear analysis in milling of medium carbon steel with coated cemented carbide inserts using different machining lubrication/cooling systems
Tool wear analysis in milling of medium carbon steel with coated cemented carbide inserts using different machining lubrication/cooling systems
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DOI：
10.1016/j.wear.2010.12.046
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发表时间：
2011-07
期刊：
影响因子：
5
通讯作者：
R. B. D. Silva;J. Vieira;R. Cardoso;H. C. Carvalho;E. Costa;Á. R. Machado;R. F. Ávila
中科院分区：
文献类型：
--
作者：
R. B. D. Silva;J. Vieira;R. Cardoso;H. C. Carvalho;E. Costa;Á. R. Machado;R. F. Ávila
目前，在竞争激烈的制造业中，高生产率、高质量和低成本是基本原则。这主要是通过使用高切削速度和进给率来实现的。然而，在这些条件下，切削区的高温会缩短刀具寿命，并对部件的尺寸精度和表面完整性产生不利影响。其他性能如刀具的强度、硬度和耐磨性也会受到影响。因此，有必要找到最佳切削条件（切削速度、进给速度、加工环境、刀具材料和几何形状），以生产符合项目要求的部件，并具有相对较高的生产率。已知的是，当适当地选择和应用切削液时，由于流体的润滑、冷却和切屑冲洗功能，切削液用于最小化与加工期间刀具的切削刃处的高温和高应力相关联的问题。此外，流体的有效性取决于它们渗透切屑-工具界面并在最短的可用时间内通过化学侵蚀或通过物理吸附形成薄层的能力，该薄层具有比界面中的材料的强度低的剪切强度。如果切削液或任何其他加工环境（大气和氩气）的有效性影响刀具磨损率和失效模式，则了解刀具磨损机制对于改进和开发更好的刀具材料和设计至关重要。了解这一过程将有助于最大限度地减少刀具磨损，从而确保更高的生产率。本文介绍了两种加工环境（干和湿）的刀具磨损和表面质量的影响，在端铣AISI 1047钢硬质合金刀具进行了比较研究。通过三种不同的技术将流体引导至切割区：溢流、降低流速和MQL。结果表明，采用减流量系统加工时，可获得更长的加工长度值和更高的材料加工去除量。此外，该系统还可防止碎屑。对磨损刀具的SEM分析表明，切削过程中刀具的磨损机制受切削环境的影响。
Currently, higher production rate with required quality and low cost is the basic principle in the competitive manufacturing industry. This is mainly achieved by using high cutting speed and feed rates. Nevertheless, elevated temperatures in the cutting zone under these conditions shorten tool life and adversely affect the dimensional accuracy and surface integrity of component. Other properties such as the strength, hardness and wear resistance of the tool can also be affected. Thus it is necessary to find optimum cutting conditions (cutting speed, feed rate, machining environment, tool material and geometry) that can produce components in accordance with the project and having a relatively high production rate. It is known that cutting fluids, when properly chosen and applied, are used to minimize problems associated with the high temperature and high stresses at the cutting edge of the tool during machining because of the lubrication, cooling, and chip flushing functions of the fluids. Also, the effectiveness of fluids depends on their ability to penetrate the chip-tool interface and to form a thin layer in the shortest available time, either by chemical attack or by physical adsorption, with lower shear strength than the strength of the material in the interface. If the effectiveness of cutting fluids or any other machining environment (atmospheric air and argon) affects tool wear rate and failure modes, the understanding of the tool wear mechanisms becomes essential for the improvement and development of better tool materials and designs. The knowledge of this process will help to minimise tool wear, thus ensuring a higher production rate. This paper presents a comparative study of the influence of two machining environments (dry and wet) in tool wear and surface quality during end milling of AISI 1047 steel with carbide tools. Fluids were directed to the cutting zone by three different techniques: flooding, reduced flow rate and MQL. The results showed that longer machined length values and higher material machining removal volume were obtained when machining using reduced flow rate system. Also, this system prevent chipping. SEM analysis of worn tools indicated that the wear mechanisms existing during machining are affected by machining environment.