Influence of High-pressure Flushing through the Rake Face of the Cutting Tool

doi:10.1016/S0007-8506(07)61162-7

CIRP Annals

Volume 41, Issue 1, 1992, Pages 101-106

https://doi.org/10.1016/S0007-8506(07)61162-7 Get rights and content

Abstract

The influence of flushing in metal cutting, including flow rate, composition and type of coolant, coolant pressure and direction, IS the subject of many investigations. In the current study high pressure flow was used, penetrating through the cutting tool's rake face and reducing the temperatures in the most critical area. During the investigation the pressure was increased up to 25 bar. Mainly grooving operations were investigated, in which chip symmetry simplifies fine analysis. It was found that flow rate and pressure have a significant influence on tool life and wear behavior as well as on the chip shape and the metallurgical structure of the chip itself. The narrowing and curling effect of the chip, improving chip exit from the slot, is viewed as related to temperature reduction. The investigation covered different cutting tool materials and different workpiece compositions. It was found that the phenomenon of built-up edge was minimized, especially when machining stainless steel and similar high alloy materials.

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The advantages of HPC mentioned above mainly derive from its ability of delivering high-pressure coolant to the contact regions between tool and chip/workpiece, which gives HPC outstanding cooling and lubrication ability. Wertheim et al. (1992) applied high pressrue flow in metal cutting processes and claimed that HPC can get good access to cutting heat sources by seeping into cutting regions. Sharma et al. (2009) reviewed the role of HPC in turning and pointed out that HPC can penetrate the tool/workpiece interface to create hydraulic wedge, resulting in alteration of chip flow conditions and reduction of tool-chip contact length.
As a novel machining process, high-speed ultrasonic vibration cutting (HUVC) has been successfully applied for high-speed machining of titanium alloys recently. To sufficiently exploit its cutting advantage over conventional cutting (CC), advanced cooling method should be employed in HUVC. In this research, high-pressure coolant (HPC) was firstly introduced to HUVC process and its influences on cutting performance of HUVC titanium alloy were studied, including tool life and wear mechanism, surface quality, cutting temperature and cutting force. The results showed that when cutting speed is 400 m/min, the tool life in HUVC can reach 7.3 times of that in CC if HPC of 200 bar was applied. Besides, the machined surface quality in a successive cutting process in HUVC was significantly improved by applying HPC. In addition, the temperature in HUVC can be reduced for 55 % at 300 m/min compared to CC. Furthermore, the analysis of wear mechanism showed that HUVC with HPC can successfully suppress the occurrence of adhesion wear.
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With more advanced materials, e.g. superalloys, applied in various high-value industries, the cutting tool performance is facing critical challenges due to the complex properties of those materials such as high strength at high temperature, which thereby lead to severe thermomechanical loads and result in accelerated tool wear [1–4]. High pressure coolant is of advantage to reduce the cutting temperature and enhance chip control in superalloys machining to enable adequate surface integrity and cutting tool performance [5–7]. However, the conventional solutions (Fig. 1a) for high-pressure cutting fluid delivery rely on “macro-nozzles” (i.e. dimensions comparable with those of the cutting tools) positioned outside the chip-tool interface that miss to deliver the coolant at the critical tool-chip/workpiece contact zones efficiently [6,8].
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The exceptional properties of Heat Resistant Super Alloys (HRSA) justify the search for advanced technologies that can improve the capability of machining these materials. One such advanced technology is the application of a coolant at high pressure while machining, a strategic solution known for at least six decades. The aim is to achieve extended tool life, better chip control and improved surface finish. Another aim is to control the temperature in the workpiece/tool interface targeting for optimum cutting conditions. In most of the existing applications with high-pressure coolant media, the nozzles are positioned on the rake face side of the insert and they are directed towards the cutting edge (the high-temperature area). The coolant is applied at high-pressure to improve the penetration of the cooling media along the cutting edge in the interface between the insert and workpiece material (chip) as well as to increase chip breakability. However, the corresponding infusion of coolant media in the interface between the flank face of the insert and the work material (tertiary shear zone) has been previously only scarcely addressed, as is the combined effect of coolant applications on rake and clearance sides of the insert. The present work addresses the influence of different pressure conditions in (flank: 0, 4 and 8 MPa; rake: 8 and 16 MPa) on maximum flank wear, flank wear area, tool wear mechanism, and overall process performance. Round uncoated inserts are used in a set of face turning experiments, conducted on the widely used HRSA “Alloy 718” and run in two condition tests with respect to cutting speed (45 (low) and 90 (high) m/min). The results show that an increase in rake pressure from 8 to 16 MPa has certainly a positive impact on tool life. Furthermore, at higher v_c of 90 m/min, cutting edge deterioration: due to an extensive abrasion and crack in the wear zone were the dominant wear mechanism. Nevertheless, the increase in coolant pressure condition to 16 MPa reduced the amount of abrasion on the tool compared to 8 MPa. At the lower cutting speed, no crack or plastic deformation or extensive abrasion were found. When using 8 MPa pressure of coolant media on the flank, the wear was reduced by 20% compared to flood cooling conditions. Application of high-pressure cooling on the flank face has a positive effect on tool life and overall machining performance of Alloy 718.
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However, turning often generates long chips during machining because the tool surface is continuously in contact with the workpiece during the cutting process. For this reason, it is difficult to supply coolant to the interface between the chip and the tool even if a large amount of coolant is used [1]. Therefore, insufficient lubricity of the tool surface can cause adhesion to the tool.
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Influence of High-pressure Flushing through the Rake Face of the Cutting Tool

Abstract

CIRP Annals

CIRP Annals

CIRP Annals

Temperaturbelastung von Hartmetallwerkzeugen bei Schnittunterbrechungen