Research on Tool Failure Mechanism of PRMMCs with Ultrasonic Assistance

Abstract

In this paper, the experimental research on the tool failure mechanism using YG6 and PCD tool cutting Particular Reinforced Metal Matrix Composites?PRMMCs? with ultrasonic cutting and common cutting was carried out, and it was discovered that: (1) the tool wear of ultrasonic cutting is less than that of common cutting, the cutting speed and feed speed have greater effect on tool wear and the cutting depth has little effect on it, the tool wear decreases with the increase of cutting speed and feed speed, and with the reduction of cutting depth, (2) the wear of PCD tool is about 1/10 of YG6’s with ultrasonic cutting the same distance, this is very similar to common cutting, (3) the modality of tool wear mainly shows the rake face wear, the flank wear and the tool breakage. When the distance of the cutting is short, the crater wear is not obvious on the rake face of YG6 tool, and the flank wear appears reverse triangle near the tip of tool under the two cutting ways. The PCD tool find no significant wear, but a serious tipping, (4) the tool wear of ultrasonic cutting is mainly abrasive wear, but it is weaker than that of common cutting, this is an important reason why the ultrasonic cutting can reduce the tool wear.