Abstract
A thin-walled spherical shell made of pure iron material is a key part of precision physical experiments. Tool wear characteristics of freeform surface parts are significantly different from those of single-point turning due to the movement of the contact point between the tool and the workpiece, which affects the form accuracy and surface integrity of workpiece. However, there is lack of a comprehensive understanding of the tool wear characteristics in machining pure iron materials. Therefore, we proposed the mathematical model to investigate the wear characteristics of cemented carbide tool further when spherical shell turning pure iron materials. The results show that uniform flank wear land and notable notch wear occur when turning end face, but notch wear disappears and only flank wear land exists when turning spherical shell. Based on major notch position and minor notch position, a mathematical model is developed to explain formation mechanisms of flank wear land during turning spherical shell of pure iron materials. Theoretical and experimental results show that flank wear land results from the major and minor notch movement. Spherical shell turning and end face turning have the same wear mechanisms, mainly composed of adhesive wear, diffusion wear, and oxidation wear.
Highlights
Pure iron materials are widely used in industries such as national defense, energy, and power electronics due to its excellent plasticity, impact resistance, and electromagnetic properties
Work hardening and plasticity deformation tend to be serious, and pure iron is easy to be adhered on tool face to form built-up layer (BUL) and built-up edge (BUE), which leads to rapid tool wear
The size of flank wear land is used as a tool life criterion for turning spherical shell of pure iron materials
Summary
Pure iron materials are widely used in industries such as national defense, energy, and power electronics due to its excellent plasticity, impact resistance, and electromagnetic properties. Kong et al.[8] observed two V-shaped notches located at the major and minor cutting edge respectively, and uniform flank wear land in the process of turning pure iron materials They thought that the formation mechanisms of notch wear were the comprehensive outcomes of adhesive wear, diffusion wear and oxidation wear. Kong et al.[8] believed the position of notch wear was not at the depth of the cut line, but outside the cutting area They thought the formation mechanisms of notch wear in turning pure iron material are the comprehensive results of adhesion wear, diffusion wear, and oxidation wear. Based on notch wear position of turning pure iron end faces, the formation mechanism of flank wear land is analyzed during turning spherical shells This will lay the foundation for improving tool life, machining surface quality and machining accuracy during cutting pure iron curved surface parts
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