Study on the protective effect of built-up layer in dry cutting of stainless steel SUS304

Song, Xiaoqi; Takahashi, Yoshihiro; He, Wei; Ihara, Takeshi

doi:10.1016/j.precisioneng.2020.05.010

Cited by 22 publications

(21 citation statements)

References 17 publications

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“…5. It can be concluded that the BUL/BUE formation conditions in dry cutting of SUS304 are given as below: at low cutting speeds (5-20 m/min), BUE (ℎ x >100 µm) forms around the cutting edge; at cutting speeds equal to or above 40 m/min, BUL (ℎ x <100 µm), which resembles a water drop, forms on the rake face, which has reported in our previous study (Song et al, 2019a(Song et al, , 2020.…”

Section: Experimental Study Of the Effects Of Bul/buesupporting

confidence: 50%

“…To gain a deeper understanding of the BUL/BUE formation phenomenon during cutting metal, in our previous studies (Song et al, 2017b(Song et al, , 2019a, the present authors firstly conducted the thermodynamic analysis of BUL/BUE formation to clarify its formation mechanisms and to predict its formation condition. It was also confirmed that BUL can function as a protective layer on the tool rake face and reduce the tool wear formation when cutting difficult-to-cut materials using the uncoated cemented carbide tool (Song et al, 2017b(Song et al, , 2018(Song et al, , 2019b(Song et al, , 2020. Thus, we can realize the self-protective tool Fig.…”

Section: Introductionmentioning

confidence: 77%

“…BUE, which can grow up to a noticeable size around the cutting edge, appears at low cutting speeds, e.g., 1-60 m/min for cutting carbon steels (Childs, 2013;Hoshi and Hoshi, 1981;Song et al, 2017a) and 5-20 m/min for cutting stainless steel (Song et al, 2019a). BUL is a thin and stable structure (the thickness is less than 100 µm) formed on the tool rake face when cutting at higher cutting speeds (Song et al, 2017a(Song et al, , 2019a or cutting difficult-to-cut materials (Song et al, 2017b(Song et al, , 2018(Song et al, , 2019b(Song et al, , 2020. BUL/BUE can change the shape of tool and replace the cutting tool to perform the actual cutting (Hoshi and Hoshi, 1981).…”

Section: Introductionmentioning

confidence: 99%

“…BUL/BUE can change the shape of tool and replace the cutting tool to perform the actual cutting (Hoshi and Hoshi, 1981). Figure 1 shows an example of the BUL/BUE formation (Song et al, 2019a(Song et al, , 2020. It is from the dry cutting of SUS304 stainless steel using the uncoated cemented carbide tool, at a cutting speed range of 5-140 m/min, a feed rate of 0.05 mm/rev, and a width of cut of 1 mm after cutting 60 s. Figure 2 shows the 2D profiles of cutting tools in Fig.…”

Section: Introductionmentioning

confidence: 99%

“…It also has a high tendency to form BUL during cutting due to its high work hardening rate and high chemical affinity. The BUL formation condition and its protective effect in dry cutting of SUS304 have been investigated in our previous study (Song et al, 2019a(Song et al, , 2020. However, until the present time, the reason for the protective effect of BUL has not been examined in detail and it was not possible to evaluate the effects of the size of BUL on the tool wear formation using an analytical method.…”

Section: Introductionmentioning

confidence: 99%

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Effects of the size of built-up layer on the wear of cemented carbide tools in cutting of SUS304 stainless steel

Song

Takahashi

et al. 2021

JAMDSM

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Built-up layer (BUL) formed on the tool rake face during cutting has the tool protective effect. As BUL can change the shape of tool resulting in variation of rake angle and edge radius, it may have significant influences on the cutting phenomena such as tool wear, cutting forces, and surface integrity. SUS304 stainless steel is very difficult to cut, leading to the rapid tool wear and poor surface quality. It also has a high tendency to form BUL during cutting due to its high work hardening rate and high chemical affinity. To actively and purposefully utilize BUL, the effects of the size of BUL on the wear of uncoated cemented carbide tools in dry cutting of SUS304 were investigated using the experimental and analytical methods in this study. The model for cutting processes included the effect of the size of BUL/BUE was presented. The cutting parameters were chosen to induce the stable BUL formation. After cutting, the worn cutting tools were analyzed using the laser confocal microscopy and scanning electron microscopy. It was confirmed that BUL can reduce the tool flank wear rate in the steadystate wear when its height is equal to or less than the uncut chip thickness. The results also showed that BUL formed at cutting speed 40 m/min not only can reduce the tool flank wear rate but also has few influences on the amplitude variation of cutting forces and surface roughness. Meanwhile, using the obtained experimental results and proposed model, simulation was conducted to evaluate the effects of the size of BUL on the tool flank wear formation. It was confirmed that BUL, especially when its height is close to the uncut chip thickness, which reduces the real rake angle to negative, can reduce the normal stress on the tool flank face and lead to a decrease in the tool flank wear rate.

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Section: Experimental Study Of the Effects Of Bul/buesupporting

confidence: 50%