Detailed analysis of microstructure of intentionally formed built-up edges for improving wear behaviour in dry metal cutting process of steel

Kümmel, Johannes; Gibmeier, Jens; Müller, Erich; Schneider, Reinhard; Schulze, Volker; Wanner, A.

doi:10.1016/j.wear.2013.12.012

Cited by 64 publications

(42 citation statements)

References 15 publications

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“…Tool wear and the influence of BUE while machining titanium alloys were investigated by Hartung and Kramer [14], who have shown that the formation of an adhesion layer helps to prevent sliding at the tool chip interface and hence improves tool life. Recently, Kümmel et al [15,16] used this idea to improve tool life by creating dimples on the tool surface, which increases BUE adhesion on the cutting tool. Oliaei and Karpat [17] studied microscale machining of titanium alloy via micro turning tests and reported the protective effect to stable BUE on the tool.…”

Section: Introductionmentioning

confidence: 99%

Investigating the influence of friction conditions on finite element simulation of microscale machining with the presence of built-up edge

Oliaei

2016

Int J Adv Manuf Technol

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In micromachining, the uncut chip thickness is less than the cutting tool edge radius, which results in a large negative effective rake angle. Depending on the material properties, this large negative rake angle promotes built-up edge (BUE) formation. A stable BUE acts like a cutting edge and affects the mechanics of the process. The size of the BUE increases with increasing uncut chip thickness and cutting speed. It also creates a positive rake angle, but it decreases the clearance angle of the tool. A method of including BUE formation in finite element simulations is to use sticking friction conditions at the tip of the tool. However, this approach is shown to be insufficient to simulate BUE formation in microscale machining. Therefore, the cutting edge is modified with the experimental BUE size in the finite element simulations based on experimental measurements. The influence of friction models between BUE and the work material has been investigated, and the study identifies friction coefficients that yield good agreements with experimental results. The finite element model is shown to be capable of simulating process forces and chip shapes for uncut chip thickness values larger than minimum uncut chip thickness.

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Section: Introductionmentioning

confidence: 99%

Investigating the influence of friction conditions on finite element simulation of microscale machining with the presence of built-up edge

Oliaei

2016

Int J Adv Manuf Technol

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“…As the cutting speed increased, the sliding velocity of the chip that formed during machining increased tremendously. As a result, the force from the sliding chip slid the BUE immediately, leading to a gradual decrease in the BUE structure [7].…”

Section: Methodsmentioning

confidence: 99%

Observation of Built-up Edge Formation on a Carbide Cutting Tool with Machining Aluminium Alloy under Dry and Wet Conditions

et al. 2017

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Abstract. This paper presents the morphology of built-up edge (BUE) formation under wet and dry conditions with low and high cutting speeds. The workpiece materials and cutting tools selected for this work were aluminium alloy and canela carbide inserts graded PM25. The cutting tools underwent turning operation machining tests and their performance was evaluated by the flank wear and observation of the tool wear area. The machining tests were conducted at different spindle speeds and feed rates while the cut depth was kept constant. The analysis showed that formation of the BUE was dominant at low cutting speeds in dry conditions, but in wet conditions at high cutting speeds, a better performance was exhibited in terms of wear analysis.

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“…The cutting tools were examined after different cutting lengths, where the built-up edge and the flank wear were documented by means of light optical microscopy. For the measurement of flank wear land width (VB), radius wear and built-up edge height the same method was applied as described in [1]. The average values of wear sizes were recorded after defined cutting lengths to reveal the wear evolution.…”

Section: Methodsmentioning

confidence: 99%

Effect of Built-Up Edge Formation on Residual Stresses Induced by Dry Cutting of Normalized Steel

Kümmel

Gibmeier

Schulze

et al. 2014

AMR

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Abstract. The tool and workpiece surface layer states of the tribosystem uncoated WC-Co cutting tools vs. normalised SAE 1045 workpiece material are studied in detail for a dry metal cutting process. Within the system the cutting parameters (cutting speed, feed rate, cutting depth) determine the wear state of the cutting tool and the resulting surface layer state (residual stress) in the workpiece. As the built-up edge can be used as a possible wear protecting layer [1] the influence of built-up edge and wear behaviour of the cutting tool was examined with respect to the workpiece surface layer state for knowledge based metal cutting processing. Small compressive stresses are induced in the surface layer, that are nearly homogeneous for the highest builtup edge, which lead to the lowest tool wear in combination with lowest cutting temperature.

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Detailed analysis of microstructure of intentionally formed built-up edges for improving wear behaviour in dry metal cutting process of steel

Cited by 64 publications

References 15 publications

Investigating the influence of friction conditions on finite element simulation of microscale machining with the presence of built-up edge

Investigating the influence of friction conditions on finite element simulation of microscale machining with the presence of built-up edge

Observation of Built-up Edge Formation on a Carbide Cutting Tool with Machining Aluminium Alloy under Dry and Wet Conditions

Effect of Built-Up Edge Formation on Residual Stresses Induced by Dry Cutting of Normalized Steel

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