Abstract
Chip evacuation is a critical issue in metal cutting, especially continuous chips that are generated during the machining of ductile materials. The improper evacuation of these kinds of chips can cause scratching of the machined surface of the workpiece and worsen the resultant surface quality. This scenario can be avoided by using a properly designed chip breaker. Despite their relevance, chip breakers are not in wide-spread use in polycrystalline diamond (PCD) cutting tools. This paper presents a systematic methodology to design chip breakers for PCD turning inserts through finite element modelling. The goal is to evacuate the formed chips from the cutting zone controllably and thus, maintain surface quality. Particularly, different scenarios of the chip formation process and chip curling/evacuation were simulated for different tool designs. Then, the chip breaker was produced by laser ablation. Finally, experimental validation tests were conducted to confirm the ability of this chip breaker to evacuate the chips effectively. The machining results revealed superior performance of the insert with chip breaker in terms of the ability to produce curly chips and high surface quality (Ra = 0.51–0.56 µm) when compared with the insert without chip breaker that produced continuous chips and higher surface roughness (Ra = 0.74–1.61 µm).
Highlights
Given their high performance under severe working conditions, via mechanical and thermal stresses and harsh chemical environments [1,2], superalloys and advanced materials have been widely used in the manufacturing of components for jet engines [2], turbochargers [3] and aerospace [4]applications
This study used a systematic approach to develop tailored, original chip breakers in polycrystalline diamond assistathe removal ofapproach chips generated under specific cutting conditions
3D geometry polycrystalline inserts, to assist thefor removal of chips generatedThen, underthe specific cutting polycrystalline diamond inserts, to assist the removal of chips generated under specific cutting was produced by the ablation of sequential of ablateddesign material the PCDchip insert usingThen, laser conditions
Summary
Given their high performance under severe working conditions, via mechanical and thermal stresses and harsh chemical environments [1,2], superalloys and advanced materials have been widely used in the manufacturing of components for jet engines [2], turbochargers [3] and aerospace [4]. Lach Diamond, Diamond, and others to integrate non-conventional technologies in their production processes in order to introduce chip-breaker geometries in their PCD inserts [28,29]. Researchers have studied different methodologies to optimize chip breakers design, experimentally [16] and combining experimentation and simulation [14,31], but most of them restricted their work to non-PCD insert tools. The proposed approach utilizes finite element method (FEM), due to its high ability to accurately simulate the chipping process [32], taking into account the machining process parameters and the material to be machined Following this introduction section, there is a description of the methodology used, based on a finite element (FE) study, to design a customized chip-breaker. There is an assessment of the results and, afterwards, conclusions are drawn
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