Coated carbide tool failure analysis in high-speed intermittent cutting process based on finite element method

Proceedings of the Institution of Mechanical Engineers, Part B:

Wang

et al. 2017

Self Cite

The aim of this investigation is to identify the Al 2 O 3-(W, Ti)C ceramic fracture modes and failure mechanisms under different cutting speeds and feed rates during intermittent turning of hardened 20CrMnTi steel. The failure surfaces of the cutting tools were examined by digital optical microscope and scanning electron microscope. The cutting forces and transient temperature in the intermittent turning process were measured during the entire life cycle. The experimental results showed that the cutting forces exhibited an increasing trend with the tool failure progression, which in turn accelerated the tool failure progression. The main failure modes of ceramic tools were wear and micro-chipping in the initial stage and final fractures, resulting from mechanical damage and thermal damage in intermittent turning processes. And the cutting temperature increased with the increase in cutting speed. The cutting speeds and feed rates were closely correlated with ceramic tool fracture modes and failure mechanisms. Furthermore, the combination of cutting parameters was divided into four regions with different fracture modes and failure mechanisms of cutting tools according to the fracture morphology of cutting tools. This partitioning analysis can provide a basis for the design and development of different ceramic cutting tools with the desired properties for different applications.

Section: Effect Of Cutting Parameters On Tool Lifementioning

confidence: 99%

Failure analysis of ceramic tool in intermittent turning of hardened steel

Proceedings of the Institution of Mechanical Engineers, Part B:

Wang

et al. 2017

Self Cite

“…The stress variable rule on cutting tools was investigated to reveal the failure mechanisms based on FEM. 10 Moreover, the effects of key machining parameters on the cutting force and surface roughness were estimated based on FEM. [11][12][13][14] And both experimental and finite-element-based approaches were adopted to research the effect of coated textured tools on cutting performance.…”

Section: Introductionmentioning

confidence: 99%

Fatigue failure analysis of ceramic tools in intermittent cutting harden steel based on experiments and finite element method

Proceedings of the Institution of Mechanical Engineers, Part B:

Gong

et al. 2019

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The major concern of this article is the fatigue failure mechanisms of ceramic cutting tools with the help of intermittent turning experiment and simulation. Finite element simulation was adopted to analyze the spatial and temporal distribution of the stress on the cutting tools. The crack initiation and expansion life in the different positions was researched based on the fatigue crack model. The experiment results showed that the fracture area of flank face reduced with the increase in feed rates, while the fracture area and damage depth of rake face both increased. Through the simulation of fatigue crack, it could be inferred that fatigue fractures were caused by coalescence of cracks. When the feed rate was greater than or equal to 0.2 mm, tool failure was mainly manifested as fatigue fracture of the rake face. And the results of fatigue crack propagation simulation well predicted the cutting tool life. A novel research method for tool fatigue failure was provided.

“…Ghani et al [18] found that the crack initiated and propagated at the cutting edge due to the effect of cyclic loading in intermittent milling titanium alloy. Wang et al [19] investigated the failure mechanisms of coated carbide tool in milling Ti-6Al-4V based on the finite element method and found that the tool failure mechanism was brittle fracture.…”

Section: Introductionmentioning

confidence: 99%

Wear and breakage of coated carbide tool in milling of H13 steel and SKD11 hardened steel

Gong

et al. 2019

SN Appl. Sci.

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In the present paper, the wear and breakage mechanisms of coated carbide tools are investigated in milling of H13 steel (HRC 30-35) and SKD11 hardened steel (HRC 58-62). The experiment results indicate that the hardness of workpiece has a dominant effect on tool failure patterns. Due to the low hardness of H13 steel, low-stress-repeated impact load on the tool induces the generation of cracks, but not enough to cause tool fracture. Thus, tool failure pattern is flank wear in milling of H13 steel. In contrast, the high-stress-repeated impact load facilitates the initiation and propagation of cracks and ultimately leads to breakage of rake face when milling SKD11 hardened steel. The geometry model of tool wear and breakage is established to explore the variation of tool angle. It is found that the flank wear reduces the clearance angle, while the breakage of rake face decreases the rake angle. In addition, the effect of tool wear and breakage on the cutting forces and chip formation is studied. The flank wear increases the friction coefficient between tool and H13 steel, and the breakage of rake face increases chip deformation and reduces the sharpness of cutting edge, both of which result in the increase in cutting forces. Furthermore, the wave-shaped chips are formed throughout milling of H13 steel, while the breakage of rake face results in the curling and separation of sawtooth chips when milling SKD11 hardened steel.