Effect of Cutting Edge Angle of PCD Tool with Chip Breaker on Chip Flow

doi:10.12382/bgxb.2023.1051

Abstract

Abstract:

A tool angle can be reasonably selected to improve the chip control effect of polycrystalline diamond (PCD) tools with chip breakers. The cutting process is observed by finite element simulation and high-speed photography, and the influence of cutting edge angle on chip flow direction is analyzed. A concept of chip contact rate is put forward to measure the influence of chip breaker on chip flow direction, the types of chip are collected and counted, the relation curve between cutting edge angle and chip contact rate is established, and the reasonable value range of cutting edge angle is determined. The deflection angle parameters of chip breaker are presented, and the relation curve between the deflection angle and the chip contact rate is established. The results show that the increase in the cutting edge angle will weaken the control effect of chip breaker on the chip flow direction. When the cutting edge angle is in the range of 75°- 95°, the chip can flow to the workpiece surface and break to form C-shaped, 6-shaped and compact short spiral chips. and the chip breaking effect under the condition of unreasonable cutting edge angle can be improved by adjusting the chip deflection angle. Selecting the reasonable cutting edge angle and chip breaker deflection angle can improve the chip contact rate of PCD tool with chip breaker, realize the effective chip breaking and improve the excellent chip ratio.

Key words: polycrystalline diamond tool, chip flow direction, chip breaking, cutting edge angle

CLC Number:

TG712

WANG Jiawei, YU Aibing, LI Yi, YE Jiawang, ZHAO Jiazhen, QI Shaochun. Effect of Cutting Edge Angle of PCD Tool with Chip Breaker on Chip Flow[J]. Acta Armamentarii, 2024, 45(12): 4488-4499.

Figures/Tables 17

Fig.1 PCD tool with chip breaker

Fig.2 Finite element cutting model

Table 1 J-C material parameters of 7075-T651 aluminium alloy[16-17]

参数	取值
弹性模量/GPa	71.7
泊松比	0.33
熔点/K	908
比热容/(J·kg^-1·K^-1)	0.786T+839.2
热导率/(W·m^-1·K^-1)	-0.0002T²+0.1366T+128.63
热膨胀系数/(μm·m^-1·K^-1)	25.2
密度/(kg·m^-3)	2810
A/MPa	527
B/MPa	575
n	0.72
c	0.017
m	1.61
$ε · 0$	1
T₀	25
T_m	635
D₁	0.110
D₂	0.572
D₃	-3.446
D₄	0.016
D₅	1.099

Table 1 J-C material parameters of 7075-T651 aluminium alloy[16-17]

参数	取值
弹性模量/GPa	71.7
泊松比	0.33
熔点/K	908
比热容/(J·kg^-1·K^-1)	0.786T+839.2
热导率/(W·m^-1·K^-1)	-0.0002T²+0.1366T+128.63
热膨胀系数/(μm·m^-1·K^-1)	25.2
密度/(kg·m^-3)	2810
A/MPa	527
B/MPa	575
n	0.72
c	0.017
m	1.61
$ε · 0$	1
T₀	25
T_m	635
D₁	0.110
D₂	0.572
D₃	-3.446
D₄	0.016
D₅	1.099

Table 2 Physical properties of PCD tool[17]

参数	数值
弹性模量/GPa	900
泊松比	0.1
比热容/(J·kg^-1·K^-1)	471.5
导热系数/(W·m^-1·K^-1)	100
密度/(kg·m^-3)	3500

Fig.3 Chip contrast

Fig.4 Simulated results of PCD tool with chip breaker at different cutting edge angles

Fig.5 Chip breaking condition

Fig.6 High-speed photography of the cutting process of PCD tool at different cutting edge angles

Table 3 Comparison of analyzed and experimental results

κ_r	ψ_λ/(°)			η/(°)
κ_r	实验值	仿真值	相对误差/%	实验值	仿真值	相对误差/%
90	11	10	9.09	23	20	13.04
95	16	15	6.25	15	16	6.67
105	29	33	13.79	11	10	9.09

Fig.7 Chip curling process

Fig.8 Chip shapes produced by tools with chip breaker at differentcutting edge angles

Fig.9 The proportion of all kinds of chips

Fig.10 S-κr relationship curve of PCD tool with chip breaker

Fig.11 Schematic diagram of chip breaker parameters

Fig.12 Schematic diagram of deflection angle of chip breaker

Fig.13 S-αr relationship curve of PCD tool with chip breaker

Fig.14 Chip shape at different deflection angles of chip breaker

References 26

[1]	何耿煌, 鄢国洪, 李凌祥, 等. 典型钛合金TC17车削过程鳞刺生成规律及其抑制措施[J]. 中国机械工程, 2020, 31(13):1585-1592.
	HE G H, YAN G H, LI L X, et al. Scale thorn generation regularity and its inhibitory measures in turning processes of typical titanium alloy TC17[J]. China Mechanical Engineering, 2020, 31(13):1585-1592. (in Chinese)
[2]	LI Y, YU A B, QIN T, et al. Improved chip control on PCD tools by positioning of brazed chip breakers[J]. Journal of Materials Processing Technology, 2022, 308:117717.
[3]	YILMAZ B, KARABULUT Ş, GÜLLÜ A. A review of the chip breaking methods for continuous chips in turning[J]. Journal of Manufacturing Processes, 2020, 49:50-69.
[4]	SOARES R B, DE JESUS A M P, NETO R J L, et al. Comparison between cemented carbide and PCD tools on machinability of a high silicon aluminum alloy[J]. Journal of Materials Engineering and Performance, 2017, 26(9):4638-4657.
[5]	CASCÓN I, SARASUA J A, ELKASEER A. Tailored chip breaker development for polycrystalline diamond inserts:FEM-based design and validation[J]. Applied Sciences, 2019, 9(19):4117.
[6]	迟剑英, 于爱兵, 吴毛朝, 等. 聚晶金刚石刀具的断屑槽尺寸参数设计[J]. 中国机械工程, 2022, 33(3):299-309.
	CHI J Y, YU A B, WU M C, et al. Design of dimensional parameters of chip breaker groove for PCD cutting tools[J]. China Mechanical Engineering, 2022, 33(3):299-309. (in Chinese)
[7]	da SILVA T F, SOARES R B, JESUS A M P, et al. Simulation studies of turning of aluminium cast alloy using PCD tools[J]. Procedia CIRP, 2017, 58:555-560.
[8]	EBERLE G, JEFIMOVS K, WEGENER K. Characterisation of thermal influences after laser processing polycrystalline diamond composites using long to ultrashort pulse durations[J]. Precision Engineering, 2015, 39:16-24.
[27]	张华. 金属切削过程仿真及其在断屑槽性能研究中的应用[D]. 南京: 南京航空航天大学, 2004.
	ZHANG H. FEM analysis on the simulation of the metal cutting process and its application in the research of the chip breakers[D]. Nanjing: Nanjing University of Aeronautics and Astronautics, 2004. (in Chinese)
[28]	马廉洁, 左宇辰, 周云光, 等. 氧化锆陶瓷车削刀具几何参数的多目标优化[J]. 东北大学学报(自然科学版), 2020, 41(8):1129-1134. doi: 10.12068/j.issn.1005-3026.2020.08.011
	MA L J, ZUO Y C, ZHOU Y G, et al. Multi-objective optimization of tool geometry parameters in turningzirconia ceramics[J]. Journal of Northeast University(Natural Science), 2020, 41(8):1129-1134. (in Chinese)
[29]	HU R S, MATHEW P, OXLEY P L B, et al. Allowing for end cutting edge effects in predicting forces in bar turning with oblique machining conditions[J]. Proceedings of the Institution of Mechanical Engineers, Part C:Journal of Mechanical Engineering Science, 1986, 200(2):89-99.
[30]	KAYMAKCI M, KILLIC Z M, ALTINTAS Y. Unified cutting force model for turning, boring, drilling and milling operations[J]. International Journal of Machine Tools and Manufacture, 2012, 54/55:34-35.
[31]	AOKI T, SENCER B, SHAMOTO E, et al. Development of a high-performance chip-guiding turning process-tool design and chip flow control[J]. The International Journal of Advanced Manufacturing Technology, 2016, 85:791-805.
[9]	WU M C, YU A B, CHEN Q J, et al. Design of adjustable chip breaker for PCD turning tools[J]. International Journal of Mechanical Sciences, 2020, 172:105411.
[10]	GONZALO O, QUINTANA I, ETXARRI J. FEM based design of a chip breaker for the machining with PCD tools[J]. Advanced Materials Research, 2011, 223:133-141.
[11]	LI A H, ZANG J, ZHAO J. Effect of cutting parameters and tool rake angle on the chip formation and adiabatic shear characteristics in machining Ti-6Al-4V titanium alloy[J]. The International Journal of Advanced Manufacturing Technology, 2020, 107(1):3077-3091.
[12]	吕明, 郭建英. 刀-屑摩擦对斜角切削切屑流动特性影响的仿真研究[J]. 兵工学报, 2010, 31(11):1491-1497.
	LÜ M, GUO J Y. Simulation for effects of tool-chip friction on chip flow characteristics in oblique cutting[J]. Acta Armamentarii, 2010, 31(11):1491-1497. (in Chinese)
[13]	ARAI M, SATOS, OGAWA M, et al. Chip control in finish cutting of magnesium alloy[J]. Journal of Materials Processing Technology, 1996, 62(4):341-344.
[14]	KAMIYA M, YAKOU T. Role of second-phase particles in chip breakability in aluminum alloys[J]. International Journal of Machine Tools and Manufacture, 2008, 48(6):688-697.
[15]	LUO H, WANG Y Q, ZHANG P. Effect of cutting parameters on machinability of 7075-T651 aluminum alloy in different processing methods[J]. International Journal of Advanced Manufacturing Technology, 2020, 110:2035-2047.
[16]	王贵林, 于爱兵, 邹翩, 等. 考虑铲钻刀具倒棱刃口几何参数的钻削力理论模型[J]. 兵工学报, 2023, 44(6): 1733-1743. doi: 10.12382/bgxb.2022.0753
	WANG G L, YU A B, ZHOU P, et al. Theoretical model of drilling force considering geometrical parameters of chamfered edge of shape drill[J]. Acta Armamentarii, 2023, 44(6):1733-1743. (in Chinese)
[17]	JOMAA W, MECHRI O, LEVESQUE J, et al. Finite element simulation and analysis of serrated chip formation during high-speed machining of AA7075-T651 alloy[J]. Journal of Manufacturing Processes, 2017, 26:446-458.
[18]	NAKAYAMA K. A study on chip-breaker[J]. Bulletin of Japanese Society of Precision Engineering, 1962, 5:142-150.
[19]	WANG J. Development of a chip flow model for turning operations[J]. International Journal of Machine Tools and Manufacture, 2001, 41(9):1265-1274.
[20]	JAWAHIR I S, BALAJI A K. Predictive modeling and optimization of turning operations with complex grooved cutting tools for curled chip formation and chip breaking[J]. Machining Science and Technology, 2000, 4(3):399-443.
[21]	GHOSH R, DILLON O W, JAWAHIR I S. An investigation of 3-D curled chip in machining—Part 1: a mechanics-based analytical model[J]. Machining Science and Technology, 1998, 2(1):91-116.
[22]	张幼桢. 金属切削理论[M]. 北京: 航空工业出版社, 1988:278-280.
	ZHANG Y Z. Metal-cutting theoretics[M]. Beijing: Aviation industry press, 1988:278-280. (in Chinese)
[23]	中山一雄. 金属切削加工理论[M]. 北京: 机械工业出版社, 1985:187-203.
	NAKAYAMA K. Theory of metal cutting[M]. Beijing: China Machine Press, 1985:187-203. (in Chinese)
[24]	李振加, 郑敏利, 韦银利, 等. 切屑空间运动轨迹及其约束方程的研究[J]. 机械工程学报, 2001, 37(12):42-46,50.
	LI Z J, ZHENG M L, WEI Y L. Study on the trajectory of chip space and its constraint equation[J]. Journal of Mechanical Engineering, 2001, 37(12):42-46,50. (in Chinese)
[25]	陈永洁, 方宁, 师汉民, 等. 切屑的三维卷曲流动[J]. 华中理工大学学报, 1993, 21(4):1-6.
	CHEN Y J, FANG N, SHI H M, et al. Kinematic credits for three-dimensional curling of chips[J]. Journal of Huazhong University of Science and Technology, 1993, 21(4):1-6. (in Chinese)
[26]	JAWAHIR I S. Chip-forms, chip breakability and chip control[M].Berlin, Germany:Springer, 2014:178-194.