Development of a high-performance chip-guiding turning process-tool design and chip flow control
Development of a high-performance chip-guiding turning process-tool design and chip flow control
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DOI：
10.1007/s00170-015-7990-5
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发表时间：
2016-07-01
影响因子：
3.4
通讯作者：
Koide, Tomio
中科院分区：
文献类型：
--
作者：
Aoki, Tomoya;Sencer, Burak;Koide, Tomio
在一般情况下，在车削作业中使用切屑断路器来打碎切屑以处理切屑。然而，高延展性材料的切屑，如低碳钢或精加工过程中产生的薄切屑，使用传统的切屑破碎机可能不容易破碎。它们会在实际生产中造成芯片堵塞和严重的停机时间。本文提出了一种新的方法，即生成的切屑不被折断，而是先被引导克服卡屑，然后通过实现拉屑车削过程来提高传统车削操作的效率。提出了一种新的刀具几何形状，以抑制切屑的侧向卷曲，从而产生直的、连续的切屑从切削点流出，从而抑制切屑堵塞。建议的刀尖几何形状包含刻在前刀面上的“导向槽”。通过优化槽形，在不同的切屑条件下，稳健地控制切屑流动，从而引导切屑，实现有效的切屑导向。然后拉动连续流动的导向切屑，以减少前刀面上的摩擦力，提高可加工性。实验结果表明，所设计的刀具几何形状能够很好地控制切屑流动，拉屑车削工艺在硬车削加工中具有很大的潜力。
In general practice, chip breakers are used to break chips in turning operations for chip disposal. However, chips of highly ductile materials such as low carbon steel or thin chips generated in finishing operations may not be broken easily with conventional chip breakers. They cause chip-jam and significant downtime in actual production. This paper proposes a novel approach where the generated chip is not broken but guided to overcome first the chip-jam and next to improve the efficiency of conventional turning operations by realizing the chip-pulling turning process. A novel cutting tool geometry is developed to suppress the chip's side curl to generate straight continuous chip flowing away from the cutting point and hence suppress the chip-jam. The proposed tool tip geometry contains "guide grooves" engraved onto the rake face. The groove topography is optimized to control the chip flow robustly at various cutting conditions so that the cut chip can be guided for effective chip guidance. Continuously flowing guided chip is then pulled to reduce the friction force on the rake face to enhance the machinability. Experimental results show that the designed cutting tool geometry robustly controls the chip flow, and the chip-pulling turning process shows significant potential towards achieving higher machinability in hard turning.