An Investigation of the Adhesive Effect on the Flank Wear Properties of a WC/Co-based TiAlN-Coated Tool for Milling a Be/Cu Alloy
Abstract
:1. Introduction
2. Materials and Method
2.1. Materials And Experimental Setup
2.2. Calculation of Cutting Force
2.3. Wear Process and Force Condition
3. Results
3.1. Spectrum Analysis and Sticking Substance
3.2. Cutting Force and its Parameters
3.3. Wearing Capacity and Back-Scattered Electron Imaging
4. Discussion
5. Conclusions
- Four kinds of cutter surface morphology were analyzed in this paper to show the possibility of adhesive layer formation on a flank surface at cutter speeds of 150, 200, and 250 m/min, which represent three different states in the adhesive process: adhesion, shedding, and residual.
- The cutting force parameters (based on Altintas [30]) were calculated in this paper, and the results show that the force parameters produced a relatively obvious turning point at 200 m/min. The tool geometry and its variation could be the main reason for a significant variation of milling force and tool wear.
- Compared with tool surface composition under different cutting speeds, the adhesive layer content reached a peak value at 200 m/min. Additionally, the thermal–mechanical effect of the work-piece on a processed surface leads to serious adhesive–abrasion wear on the flank surface.
Author Contributions
Funding
Acknowledgments
Conflicts of Interest
Nomenclature
Symbol | Quantity Unit |
f | Feed per tooth mm/z |
Fc | Cutting force in orthogonal cutting N |
τ | Shear Stress MPa |
Ft | Thrust force in orthogonal cutting N |
v | Cutting speed m/min |
Average cutting force in orthogonal cutting N | |
n | Spindle rotate speed r/min |
Average thrust force in orthogonal cutting N | |
ap | Axial depth of cut mm |
Fx | Milling force in the X direction N |
ϕ | Shear angle deg |
Fy | Milling force in the Y direction N |
T | Torsion N |
Fz | Milling force in the Z direction N |
Ktx | Cutting parameter in the X direction |
F | Total cutting force N |
Krx | Cutting parameter in the Y direction |
h | Cut thickness mm |
Kax | Cutting parameter in the Z direction |
b | Side milling width mm |
β | Helical angle deg |
z | Tooth number |
D | Cutter diameter mm |
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Contents (wt.%) | Material Properties | ||||||||
---|---|---|---|---|---|---|---|---|---|
Be | Co | Ni | Si | Fe | Al | Cu | Tensile Strength MPa | Hardness HRC | Yield Strength GPa |
1.9 | 0.35 | 0.20 | 0.15 | 0.15 | 0.15 | Bal | 1105 | 38–44 | 128 |
V = 150 m/min | V = 200 m/min | V = 250 m/min | |||
---|---|---|---|---|---|
f/(mm·r−1) | ap/mm | f/(mm·r−1) | ap/mm | f/(mm·r−1) | ap/mm |
0.05 | 0.5 | 0.05 | 0.5 | 0.05 | 0.5 |
0.1 | 1 | 0.1 | 1 | 0.1 | 1 |
0.15 | 1.5 | 0.15 | 1.5 | 0.15 | 1.5 |
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Zuo, J.; Lin, Y.; He, M. An Investigation of the Adhesive Effect on the Flank Wear Properties of a WC/Co-based TiAlN-Coated Tool for Milling a Be/Cu Alloy. Metals 2019, 9, 444. https://doi.org/10.3390/met9040444
Zuo J, Lin Y, He M. An Investigation of the Adhesive Effect on the Flank Wear Properties of a WC/Co-based TiAlN-Coated Tool for Milling a Be/Cu Alloy. Metals. 2019; 9(4):444. https://doi.org/10.3390/met9040444
Chicago/Turabian StyleZuo, Junyan, Youxi Lin, and Ming He. 2019. "An Investigation of the Adhesive Effect on the Flank Wear Properties of a WC/Co-based TiAlN-Coated Tool for Milling a Be/Cu Alloy" Metals 9, no. 4: 444. https://doi.org/10.3390/met9040444