FEM Based Design of a Chip Breaker for the Machining with PCD Tools

Gonzalo, Óscar; Quintana, Iban; Etxarri, Jon

doi:10.4028/www.scientific.net/amr.223.133

Cited by 10 publications

(3 citation statements)

References 12 publications

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“…Although numerous tool manufacturers still base their tool-designs on try-and-see methods based on their previous experience [19], FEM is considered a reliable tool to assess the relative performance of several designs of engineering components, and has been extensively used for the design of cutting tools [32][33][34]. Gurbuz et al [35] pointed out the significance of FEM to evaluate different design geometries to determine a final design before manufacturing, which is substantially cheaper than trial and error methods.…”

Section: Chip Breaker Fe Design For a Pcd Turning Insertmentioning

confidence: 99%

Tailored Chip Breaker Development for Polycrystalline Diamond Inserts: FEM-Based Design and Validation

2019

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Chip evacuation is a critical issue in metal cutting, especially continuous chips that are generated during the machining of ductile materials. The improper evacuation of these kinds of chips can cause scratching of the machined surface of the workpiece and worsen the resultant surface quality. This scenario can be avoided by using a properly designed chip breaker. Despite their relevance, chip breakers are not in wide-spread use in polycrystalline diamond (PCD) cutting tools. This paper presents a systematic methodology to design chip breakers for PCD turning inserts through finite element modelling. The goal is to evacuate the formed chips from the cutting zone controllably and thus, maintain surface quality. Particularly, different scenarios of the chip formation process and chip curling/evacuation were simulated for different tool designs. Then, the chip breaker was produced by laser ablation. Finally, experimental validation tests were conducted to confirm the ability of this chip breaker to evacuate the chips effectively. The machining results revealed superior performance of the insert with chip breaker in terms of the ability to produce curly chips and high surface quality (Ra = 0.51–0.56 µm) when compared with the insert without chip breaker that produced continuous chips and higher surface roughness (Ra = 0.74–1.61 µm).

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Section: Chip Breaker Fe Design For a Pcd Turning Insertmentioning

confidence: 99%

Tailored Chip Breaker Development for Polycrystalline Diamond Inserts: FEM-Based Design and Validation

2019

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“…High energy beam machining is another option to produce macro surface structures on tools with high precision and acceptable efficiency. Gonzalo [17] and Elkaseer et al [18] applied laser ablation to make 3D chip-breakers on PCD insert and blades of milling tool. In addition, the electrodischarge machining (EDM) is also turned out feasible for making chip-breaker [19].…”

Section: Manufacture Approachesmentioning

confidence: 99%

“…Meanwhile, the geometry of chip-breaker had a significant effect on the cutting force value. Wu et al [22] and Gonzalo et al [17] simulated chip formation and breaking by 2D and 3D FEM models, aiming at providing theoretical instructions to the design of complex chip-breaker. Overall, FEM has shown its potential in chip-breaker design, even for the complex topographies.…”

Section: Finite Element Modeling (Fem)mentioning

confidence: 99%

From macro to micro, evolution of surface structures on cutting tools: a review

Kang

Kim

et al. 2019

JMST Adv.

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In modern tool industry, the design and manufacture of cutting tool surface have been highlighted to fulfill the ever-increasing demands of advanced manufacturing, e.g., lean production, intelligent manufacturing and Industry 4.0. Chip-breaker is a triumph of applying the specific macro structure on rake face, not only contributing to chip controlling, but also being capable to reduce cutting force and tool temperature. In recent decade, surface texturing has been emerged on tool surface, indicating that research focus of surface structures on tools is evolving from macroscale to microscale. The present study reviews functions, optimization and manufacture approaches of different scale structures on cutting tools, aiming at providing a global view of related technologies and revealing the possible developing tendency in this field. This paper could greatly facilitate future research and industrial application of tool surface modification, especially for the integrated application in multi-scale.

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