Abstract
The study proposed the chip formation steady-state model and cutting efficiency model for multi-cutters by Taylor tool life and fractal equation according to uniform chip thickness in high-speed band sawing process. Furthermore, a kind of new hook-tooth can be successfully applied on continuously uniformed chip formation in order to raise the production precision. The study developed MDOF cutting dynamics, which can be applied on multi-cutting process by Taylor tool life and fractal equations. Factors of affecting band-sawing included the cutting force, the cutting geometry, the cutting heat, the local stress-strain and the chip thickness formation uniformity. These factors had an important influence on tool wear, surface roughness, production precision and cutting efficiency in high-speed sawing process. The simulated results shown that, the wear resistance property is better at coating TiN 0.6 μm. In high-speed cutting process, the cutting improvement rate can be increased at least 13%. While the hook-tooth cutting speed achieved 120 m/min, comparing with non-coating cutting tooth, coating 0.6μm coating-layer can make the temperature decreased, obviously.
Highlights
Factors of affecting band-sawing include cutting force, cutting geometry, cutting heat, local stress-strain and chip thickness formation uniformity
Band-saw types can be distinguished from the straightcutters, wave-cutters, sinusoidal-cutters, circle-cutters and wire-saw depended on saw-blade geometry, and machining mechanism applied on multi-points cutting
The study developed MDOF cutting dynamics, which can be applied on multi-cutting process by Taylor tool life and fractal equations
Summary
Factors of affecting band-sawing include cutting force, cutting geometry, cutting heat, local stress-strain and chip thickness formation uniformity. These factors have an important influence on tool wear, surface roughness, production precision and cutting efficiency in high-speed sawing process. It is effective to improve machining quality, raise cutting efficiency and reduce the cost by controlling these factors. The study proposed cutting factors of tool geometry in band-sawing process, simulated and improved the machining characteristics and investigated the effects of vary kinds of cutters geometry in sawing process. By using the optimal process parameters, including coating factors, cutting velocity, tool geometry, tool material and workpiece material to improve cutting temperature, cutting resistance and the production qualities will achieve a better standard
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