Abstract
Results of theoretical and experimental studies aimed at establishing features of micro-cutting with abrasive grains characterized by active emission of slime and dust particles were presented. The slime particles are just partially withdrawn from the interaction zone and partially change surfaces of the tool and the workpiece of a carbon composite material, in particular, of carbon-carbon and carbon-polymer groups. The above materials possessing a complex of unique physical and mechanical properties are used in high-tech production though composites remain difficult to process materials. The problems manifest themselves to their utmost in making various apertures, shoulders, cutting of holes, processing edges. The study has shown that the phenomenon of dust and slime emission in abrasive processing of carbon-based non-dense composites and plastics results from sliding fracture and cyclic weakening of the surface non-dense layer which exhibits quasi-brittle properties under the action of fast-moving micro-indenters. Conditionality of the average slime particle sizes by normal stresses in the cutting zone and the magnitude of protrusion of diamond grains above the cutting surface of the tool was revealed. Since it was found that the particles formed during cutting are only partially withdrawn outside the cutting zone and the degree of removal decreases with an increase in the processing time, a conclusion on the cause of change in the state of the tool surface was drawn. The remaining slime and dirt change topography of the surface which results in the cutting zone temperature rise to critical values. It was shown that the use of tools with cyclic advance makes it possible to partially improve the condition of material processing which is relevant for the implementation of the processes of ring diamond drilling, processing with diamond saw blades. It was proved that the intermittent application of areas of the diamond-bearing layer reduces the phenomenon of dirt particle sticking to the surface of the working tool. Thus, the tool stays free of dirt for longer and the machining process is more efficient
Highlights
The use of new composite materials by machine-building complexes of the world’s leading countries is constantly growing
Because this study has shown that the particle sizes and movement in gaps are conditioned by the temperature at the points of contact of diamond grains with the processed material (Fig. 13)
Regularities of dust emission during the processing of composite carbon-carbon materials were obtained and it was shown that the intensity of dust emission changes with time getting lower with an increase in the processing time
Summary
The use of new composite materials by machine-building complexes of the world’s leading countries is constantly growing. Authors of [9] considered damages in a workpiece when the drill comes out of the hole during drilling linking them to conditions of tool loading In principle, these studies did not differ from those discussed above because the material itself was a component medium with no cavities and had average physical and mechanical characteristics. The lack of scientific basis for peculiarities of slime and dust emission in processing anisotropic non-dense materials necessitates studies of abrasive processing of composites taking into account the accompanying phenomena, in particular, slime and dust emission This is facilitated by active modification of these materials (such as KIMF) and their increasing use in engineering practice
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