Abstract
The paper examines the wear of end mill cutters, the parameters of a workpiece’s surface layer and the values of cutting forces during the machining of polymer concrete, which is one of the most difficult-to-cut materials. Increased abrasive wear of the active cutting edges is a result of the heterogeneous structure of this material, and it has a negative effect on the cutting process, the durability of the cutting tools as well as the roughness of the workpiece. It is very important to determine the machining parameters for this material from a tool durability and quality of machining point of view. The research was divided into two stages. In the first stage, the appropriate machining parameters were determined based on the measurement of the components of the cutting force. In the second stage, durability tests of four end mill cutters were carried out. During the tests, the component cutting forces, tool wear and surface roughness were measured. The highest tool durability was recorded for the monolithic cemented carbide cutter with coating NC Mill G9F42120N 4F. Tools made of high-speed steel should not be used for machining polymer concrete, as they exhibited the highest intensity of tool wear. The rapid loss of machinability of these tools leads to a rapid increase in cutting force and the roughness of the machined surface. From an economic point of view, cemented carbide end mill cutters with coatings seem to be the appropriate choice for machining polymer concrete.
Highlights
Modern industry is constantly looking for new construction solutions, as well as modern and ecological materials, which thanks to their properties will improve the quality of manufactured products, reduce the costs associated with the production process and increase its flexibility
Current trends in the development of machine tool construction include the application of mineral casts as substitutes for cast iron
Polymer concrete is applied to selected components of machine tools, e.g. guides or as filler for the ribs of machine tool bodies [7]
Summary
Modern industry is constantly looking for new construction solutions, as well as modern and ecological materials, which thanks to their properties will improve the quality of manufactured products, reduce the costs associated with the production process and increase its flexibility. Such materials include polymer concrete, which appears under the name. Int J Adv Manuf Technol (2020) 106:3017–3032 mineral cast It is a complex material consisting of inorganic aggregates, such as basalt, spodumene (LiAlSi2O6), fly ash, river gravel, sand, chalk, etc., bound with each other by resin [1,2,3]. In order to improve the dynamic properties of machine tool, polymer concrete with addition of styrene-butadiene rubber can be used [10]
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