Wear and breakage of TiAlN- and TiSiN-coated carbide tools during high-speed milling of hardened steel
Wear and breakage of TiAlN- and TiSiN-coated carbide tools during high-speed milling of hardened steel
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DOI：
10.1016/j.wear.2015.04.018
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发表时间：
2015-08
期刊：
影响因子：
5
通讯作者：
Chengyong Wang;Y. X. Xie;Z. Qin;Haisheng Lin;Yaohui Yuan;Qimin Wang
中科院分区：
文献类型：
--
作者：
Chengyong Wang;Y. X. Xie;Z. Qin;Haisheng Lin;Yaohui Yuan;Qimin Wang
在模具工业淬硬钢的高速加工中，如何减少涂层硬质合金刀具的磨损，提高其加工效率和质量一直是一个重要课题。本研究研究了使用两种 PVD 涂层硬质合金刀具（TiAlN 和 TiSiN）对淬火钢（SKD11/HRC 62、S136/HRC 51）进行高速加工，以确定刀具磨损和破损的机制以及刀具角度、刀具直径、刀具伸出长度、切削力和切削引起的振动对刀具的影响。结果表明，涂层硬质合金刀具的主要磨损形式包括后刀面磨损、齿条面磨损、破损和微崩角。用于淬硬钢高速铣削的涂层硬质合金刀具的破损方式为涂层剥落、崩刃和刀尖折断。由于减少了磨料磨损，涂覆 TiSiN 的切削刀具的寿命比涂覆 TiAlN 的刀具更长。加工时刀具伸长，导致切屑由螺旋切屑转变为C形切屑，并随着长度的增加而产生锯齿状切屑。选择最佳刀具伸出长度可以提供最小的切削力、较小的刀具磨损和最佳的加工质量。切削力的特征可以清晰地反映刀具磨损时的异常情况。小前角、合适的后角和大螺旋角的刀具不仅可以减小切削力，而且可以保证切削过程顺利进行，并减少刀具磨损。
In the high-speed machining of hardened steel for the die and mould industry, determining how to reduce the wear of coated carbide tools and improve their machining efficiency and quality has been an important subject. This study investigated the high-speed machining of hardened steel (SKD11/HRC 62, S136/HRC 51) using two types of PVD-coated carbide tools (TiAlN and TiSiN) to determine the mechanism of cutting tool wear and breakage and the effects of tool angle, tool diameter, tool extended length, cutting force and cutting-induced vibration on the tools. The results indicated that the dominant wear patterns of coated carbide tools included flank wear, rack face wear, breakage and micro-chipping. The modes of breakage of the coated carbide tools used for the high-speed milling of hardened steel were coating peeling, chipping and tip breakage. The lives of the cutting tools coated with TiSiN were longer than those of the tools coated with TiAlN due to reduced abrasive wear. The tool extended length during machining caused chips to transform from spiral chips into c-shaped chips and produce sawtooth chips as the length increased. The selection of the optimal tool extended length can deliver the minimum cutting force, a small degree of tool wear and the best machining quality. The characteristics of the cutting force can distinctly reflect abnormal conditions as the cutting tool wears. A tool with a small rake angle, suitable clearance angle and large helix angle will not only reduce the cutting force but also ensure a smooth cutting process and generate less cutting tool wear.