1 Introduction
2 Experimental
2.1 Design ideas of SHCCT tool
2.2 Theoretical substantiation of expected reduction in cutting force and cutting temperature
2.3 Effects of texture on cutting forces and cutting temperature
2.4 Effect of soft/hard composite coating on cutting forces and cutting temperature
2.5 Orthogonal experiments design
Coating | Elastic modulus/GPa | Density/(kg·m−3) | Thermal expansion coefficient/(10−6 K−1) | Poisson’s ratio | Thermal conductivity/(W·(m·K)−1) | Hardness/GPa |
---|---|---|---|---|---|---|
WS2 | 354 | 7 500 | 6.35 | 0.280 | 32 | – |
MoS2 | 330 | 5 060 | 10.70 | 0.125 | 37 | – |
TiN | 600 | 5 220 | 9.40 | 0.250 | 25 | 28 |
ZrN | 510 | 7 320 | 7.20 | 0.160 | 16.73 | 28–32 |
TiAlN | 440 | 5 220 | 9.20 | 0.230 | 15 | 28 |
Level | A (coating thickness)/μm | B (coating material) | C (thickness ratio of soft and hard coatings) |
---|---|---|---|
1 | 0.5 | WS2/TiN | 0.9/0.1 |
2 | 1.0 | WS2/ZrN | 0.7/0.3 |
3 | 1.5 | WS2/TiAlN | 0.5/0.5 |
4 | 2.0 | MoS2/TiN | 0.3/0.7 |
5 | 2.5 | MoS2/ZrN | 0.1/0.9 |
Group | A | B | C | Scheme |
---|---|---|---|---|
1 | 1 | 1 | 1 | A1B1C1 |
2 | 1 | 2 | 2 | A1B2C2 |
3 | 1 | 3 | 3 | A1B3C3 |
4 | 1 | 4 | 4 | A1B4C4 |
5 | 1 | 5 | 5 | A1B5C5 |
6 | 2 | 1 | 2 | A2B1C2 |
7 | 2 | 2 | 3 | A2B2C3 |
8 | 2 | 3 | 4 | A2B3C4 |
9 | 2 | 4 | 5 | A2B4C5 |
10 | 2 | 5 | 1 | A2B5C1 |
11 | 3 | 1 | 3 | A3B1C3 |
12 | 3 | 2 | 4 | A3B2C4 |
13 | 3 | 3 | 5 | A3B3C5 |
14 | 3 | 4 | 1 | A3B4C1 |
15 | 3 | 5 | 2 | A3B5C2 |
16 | 4 | 1 | 4 | A4B1C4 |
17 | 4 | 2 | 5 | A4B2C5 |
18 | 4 | 3 | 1 | A4B3C1 |
19 | 4 | 4 | 2 | A4B4C2 |
20 | 4 | 5 | 3 | A4B5C3 |
21 | 5 | 1 | 5 | A5B1C5 |
22 | 5 | 2 | 1 | A5B2C1 |
23 | 5 | 3 | 2 | A5B3C2 |
24 | 5 | 4 | 3 | A5B4C3 |
25 | 5 | 5 | 4 | A5B5C4 |
26 | Without texturing and coating | – | ||
27 | Textured without coating | – | ||
28 | Coated without texturing | A4B3C1 |
2.6 Cutting simulation
Material | Elastic modulus/GPa | Poisson’s ratio | Thermal conductivity/(W·(m·K)−1) | Specific heat capacity/(J·(kg·K)−1) |
---|---|---|---|---|
AISI-1045 (workpiece) | – | 0.30 | Change with temperature | Change with temperature |
Cemented carbide (tool) | 680 | 0.25 | 59 | 15 |
Texture structural parameters | Hole texture |
---|---|
Texture diameter/μm | 50 |
Texture depth/μm | 40 |
Texture spacing/μm | 150 |
3 Results and discussion
3.1 Cutting temperature
3.2 Main cutting force
3.3 Results of orthogonal experiments
Group | A | B | C | Scheme | Cutting temperature/°C | Main cutting force/N |
---|---|---|---|---|---|---|
1 | 1 | 1 | 1 | A1B1C1 | 77.3 | 85.7 |
2 | 1 | 2 | 2 | A1B2C2 | 75.4 | 79.1 |
3 | 1 | 3 | 3 | A1B3C3 | 114.0 | 85.1 |
4 | 1 | 4 | 4 | A1B4C4 | 171.0 | 83.3 |
5 | 1 | 5 | 5 | A1B5C5 | 120.0 | 83.7 |
6 | 2 | 1 | 2 | A2B1C2 | 106.0 | 84.5 |
7 | 2 | 2 | 3 | A2B2C3 | 91.6 | 85.3 |
8 | 2 | 3 | 4 | A2B3C4 | 141.0 | 86.7 |
9 | 2 | 4 | 5 | A2B4C5 | 197.0 | 85.2 |
10 | 2 | 5 | 1 | A2B5C1 | 86.8 | 83.0 |
11 | 3 | 1 | 3 | A3B1C3 | 139.0 | 84.5 |
12 | 3 | 2 | 4 | A3B2C4 | 109.0 | 83.0 |
13 | 3 | 3 | 5 | A3B3C5 | 179.0 | 89.4 |
14 | 3 | 4 | 1 | A3B4C1 | 109.0 | 84.1 |
15 | 3 | 5 | 2 | A3B5C2 | 98.3 | 83.4 |
16 | 4 | 1 | 4 | A4B1C4 | 184.0 | 83.7 |
17 | 4 | 2 | 5 | A4B2C5 | 131.0 | 88.8 |
18 | 4 | 3 | 1 | A4B3C1 | 62.9 | 82.2 |
19 | 4 | 4 | 2 | A4B4C2 | 134.0 | 86.8 |
20 | 4 | 5 | 3 | A4B5C3 | 108.0 | 84.2 |
21 | 5 | 1 | 5 | A5B1C5 | 204.0 | 87.0 |
22 | 5 | 2 | 1 | A5B2C1 | 70.3 | 80.3 |
23 | 5 | 3 | 2 | A5B3C2 | 95.8 | 85.1 |
24 | 5 | 4 | 3 | A5B4C3 | 158.0 | 89.4 |
25 | 5 | 5 | 4 | A5B5C4 | 120.0 | 82.9 |
26 | Without texturing and coating | – | 428.0 | 97.4 | ||
27 | Textured without coating | – | 346.0 | 90.5 | ||
28 | Coated without texturing | A4B3C1 | 314.0 | 92.2 |