On the Formation Mechanisms of Adhering Layer during Machining Metal Material

Xiao Qi Song; Yukio Takahashi; Wei Ming He; Tohru Ihara

doi:10.4028/www.scientific.net/KEM.749.39

Paper Titles

Relationship between Cutting Heat and Tool Edge Temperature in End Milling of Titanium Alloy
p.15

Influence of Micro End Mill Tool Run-Out on Machining Accuracy
p.21

Influence of Scratch Marks on Undeformed Chip Thickness in Ultra-Precision Cutting of Al-Mg Alloys
p.27

High Aspect Ratio Thin Rib Shape Processing of Carbon Material for Electrical Discharge Machining Molds
p.33

On the Formation Mechanisms of Adhering Layer during Machining Metal Material
p.39

Roundness in Drilling of Low-Rigidity Workpiece
p.46

Investigation of Grinding Fluid for Prevention of Chip Adhesion in Miniature Drilling of Glass Plate Using Electroplated Diamond Tool
p.52

Wet Core Drilling of CFRP with an Electrodeposited Diamond Core Drill - Effects of Cutting Conditions on Chip Evacuation and Core Jamming
p.58

Property and Recyclability Change of Corrosion-Inhibition-Improved Amine-Free Water-Soluble Cutting Fluid with Repeated Recycling
p.65

HomeKey Engineering MaterialsKey Engineering Materials Vol. 749On the Formation Mechanisms of Adhering Layer...

On the Formation Mechanisms of Adhering Layer during Machining Metal Material

Abstract:

Built-up Layer (BUL)/Built-up Edge (BUE) formed on the tool surface can be treated as a protective, thermal barrier or lubricant films especially in the extreme severe conditions when machining the metal materials, which can sustain the tool effective and wear resistance. In order to have a thorough understanding of the adhesion effect during machining, experiments have been carried out to investigate the performance and the formation mechanisms of adhering layer on the carbide tool in machining of aluminium alloys A6063, carbon steel S45C and difficult-to-cut hardened steel S45C (H-S45C). The morphology of tool adhered surface was examined by employing Scanning Electron Microscopy (SEM), the dimensions of adhering layer were measured by Laser Scanning Microscopy (LSM) and the elements on the tool were analyzed by Electron Probe Micro Analyser (EPMA), respectively. The atomic-scale cluster adhesive friction model is proposed to explain the tool-chip contact conditions, which considers the nature of the shear strain, shear strain rate and temperature distribution in the secondary deformation zone. The model is a dynamic model and the rate equation approach can be applied to estimate the formation process of adhering layer during machining. Results have shown that the adhering layer will give rise to BUL on the tool rake face and the BUE on the cutting edge and clearance face.