Tool wear characteristics in high-speed milling of graphite using a coated carbide micro endmill
Tool wear characteristics in high-speed milling of graphite using a coated carbide micro endmill
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使用涂层硬质合金微型立铣刀高速铣削石墨时的刀具磨损特性
DOI：
10.1243/09544054jem1326
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发表时间：
2009-03
期刊：
影响因子：
2.6
通讯作者：
Wang, C.Y.
中科院分区：
文献类型：
--
作者：
Qin, Z.;Zhou, L.;Wang, C.Y.
摘要 使用涂层硬质合金微型立铣刀进行高速铣削是模具行业石墨电极的主要精密制造技术之一。石墨的研磨和摩擦特性会导致高速铣削过程中刀具严重磨损。本文将带有AlTiN涂层的硬质合金微型立铣刀用于石墨的高速铣削。使用扫描电子显微镜彻底检查立铣刀，并推断出磨损和失效机制。研究发现，所有磨损区域几乎随刀具位移线性增加，后刀面磨损是稳定磨损阶段的主要磨损模式。在初始阶段，会出现涂层过早分层和边缘微崩裂的现象。随着磨粒磨损和冲蚀磨损机制的产生，出现了稳定磨损阶段。刀具故障的发生是由于涂层分层失效、严重碎裂和冲击疲劳剥落的产生。抛光磨粒磨损是立铣刀的主要磨损机制。刀具磨损期间没有发生元素的大扩散。提高每齿进给量和切削速度有助于提高刀具性能，减少刀具磨损并提高生产率。
Abstract High-speed milling using a coated carbide micro endmill is one of the dominant precision manufacturing techniques for graphite electrodes in the die and mould industries. The abrasive and frictional properties of graphite result in severe tool wear in high-speed milling processes. In this paper, a carbide micro endmill with an AlTiN coating is used in the high-speed milling of graphite. The endmill is thoroughly examined using a scanning electronic microscope and the wear and failure mechanisms are deduced. It is found that all the worn areas increase almost linearly with tool displacement, and flank wear is the dominant wear pattern in the steady wear stage. In the initial stage, premature coating delamination and edge microchipping occurred. The steady wear stage occurred with the creation of abrasive and erosion wear mechanisms. Tool failure occurred owing to the creation of coating delamination failure, severe chipping, and impact fatigue spalling. Polishing abrasive wear is the primary wear mechanism of the endmill. No major diffusion of elements occurred during the tool wear. Increasing the feed-per-tooth level and cutting speed facilitated the tool performance in terms of reducing tool wear and improving productivity.
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