Abstract
The efficiency of a cutting tool can be enhanced through stress–strain and temperature studies. Existing mathematical methods implement simplified boundary conditions, and experimental methods that are either inapplicable to real working conditions or lack the necessary accuracy. This study aims to develop novel experimental methods for stress–strain and temperature field analyses. The approaches entail recording the side deformation fields of the cutting tool by laser interferometry during its operation, separating the deformation fields caused by the cutting forces and heating, as well as calculating the stress–strain and temperature fields using the Young’s modulus, Poisson’s ratio, and coefficient of linear thermal expansion of the tool material. The advantages of these methods include their applicability under real cutting conditions and the possibility to study the stress–strain and temperature fields of a tool during non-stationary operation by high-speed video recording. The study proves the efficiency of the proposed methods by the orthogonal machining of difficult-to-cut steel disc using a cemented carbide tool with positive rake angle. As a result, the temperature and principal stress fields in the tool were determined. Developed methods can help in the study of cutting tool efficiency.
Highlights
The performance of the cutting tool has the greatest impact on the efficiency of the entire machining process, and methods of enhancing this performance are discoverable through the study of the stress– strain and temperature states of the tool in near-real conditions
To overcome the limitations of the above-mentioned approaches and improve the process of determining the stress and temperature fields of the cutting tool, we developed methods [9, 10] and experimental rig based on laser interferometry
The tool state may be depicted by the two-dimensional problem because the cutting tool width is narrow relative to its size, and stresses with temperature may be regarded as uniformly distributed over the tool thickness
Summary
The performance of the cutting tool has the greatest impact on the efficiency of the entire machining process, and methods of enhancing this performance are discoverable through the study of the stress– strain and temperature states of the tool in near-real conditions. Calculation methods that employ analytically obtained boundary conditions with extensive simplifications and assumptions are widely used to determine the stress–strain and temperature states of the tool [1, 2]. Many experimental methods have been developed to measure the strain–stress and temperature distributions in the cutting tool. The use of various types of strain gauges to study deformation fields is extremely challenging because of the extremely small size of the working tool involved, as well as the high temperatures involved in the cutting process. The split–tool dynamometer [3] provides an opportunity to determine the stress distributions along only tool faces
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