Abstract
This paper is based on the theoretical analysis designs of a dry cutting orthogonal test in order to study a phenomenon that the radial force is larger than the main cutting force when a PCBN (polycrystalline cubic boron nitride) tool hard turns GCr15. Finite element modelling and cutting tests show the cutting depth and the spindle speed having an impact on the main cutting force, the radial force, and the axial force. In this study, due to the shear function of the cutting process, the squeezing effect between the tool and the workpiece, and the metal softening effect of the workpiece material, the different cutting depth and the spindle speed bring about different cutting force changes, and also different spindle speeds have different effects on the three components of the total cutting force. The research result provides a basis for further study on dry turning of hardened bearing steel.
Highlights
With the advent of high hardness and difficultly-machined materials, the demand for cutting tools becomes higher and higher
(1) Under smaller cutting depths, the radial force generated in the cutting process is greater than that of the main cutting force and the axial force
With the increase of the cutting depth, the main cutting force increases, while the radial force decreases, which causes the main cutting force to be cutting force increases, while the radial force decreases, which causes the main cutting force to be greater than the radial force
Summary
With the advent of high hardness and difficultly-machined materials, the demand for cutting tools becomes higher and higher. Fernández-Abia et al presented a mechanistic model for cutting force prediction, and this model was developed for machining with nose radius tools considering the effect of the edge force due to the rounded cutting edge. They concluded that shearing and edge cutting coefficients were valid for a wide range of cutting conditions [7]. When PCBN tools are used to turn hard materials whose hardness is over 55 HRC, the main cutting force will be lower than the radial force. There is no clear explanations regarding the phenomenon that the radial force is greater than the main cutting force during the process of PCBN tool hard turning of GCr15. In order to clarify the reasons, this paper, based on finite simulation and cutting tests, designs orthogonal test methods and makes systematic theoretical analyses from the tool shear function and the metal softening effect of the workpiece material
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