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3 pages, 134 KiB

Open AccessEditorial

Friction and Wear of Cutting Tools and Cutting Tool Materials

by Guoliang Liu, Chuanzhen Huang, Xiangyu Wang, Bin Zhao and Min Ji

Lubricants 2024, 12(6), 192; https://doi.org/10.3390/lubricants12060192 - 28 May 2024

Cited by 1 | Viewed by 700

Abstract

The friction between cutting tools and the workpiece/chip can significantly affect the tool wear, cutting force, cutting temperature, machined surface integrity, and machined parts’ service performance [...] Full article

(This article belongs to the Special Issue Friction and Wear of Cutting Tools and Cutting Tool Materials)

Research

Jump to: Editorial

18 pages, 5729 KiB

Open AccessArticle

Tool Wear Prediction Model Using Multi-Channel 1D Convolutional Neural Network and Temporal Convolutional Network

by Min Huang, Xingang Xie, Weiwei Sun and Yiming Li

Lubricants 2024, 12(2), 36; https://doi.org/10.3390/lubricants12020036 - 26 Jan 2024

Cited by 3 | Viewed by 2060

Abstract

Tool wear prediction can ensure product quality and production efficiency during manufacturing. Although traditional methods have achieved some success, they often face accuracy and real-time performance limitations. The current study combines multi-channel 1D convolutional neural networks (1D-CNNs) with temporal convolutional networks (TCNs) to [...] Read more.

Tool wear prediction can ensure product quality and production efficiency during manufacturing. Although traditional methods have achieved some success, they often face accuracy and real-time performance limitations. The current study combines multi-channel 1D convolutional neural networks (1D-CNNs) with temporal convolutional networks (TCNs) to enhance the precision and efficiency of tool wear prediction. A multi-channel 1D-CNN architecture is constructed to extract features from multi-source data. Additionally, a TCN is utilized for time series analysis to establish long-term dependencies and achieve more accurate predictions. Moreover, considering the parallel computation of the designed architecture, the computational efficiency is significantly improved. The experimental results reveal the performance of the established model in forecasting tool wear and its superiority to the existing studies in all relevant evaluation indices. Full article

(This article belongs to the Special Issue Friction and Wear of Cutting Tools and Cutting Tool Materials)

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17 pages, 13322 KiB

Open AccessArticle

Effect of Composite Bionic Micro-Texture on Cutting Performance of Tools

by Tiantian Xu, Chunlu Ma, Hu Shi, Kai Xiao, Jinpeng Liu and Qinghua Li

Lubricants 2024, 12(1), 4; https://doi.org/10.3390/lubricants12010004 - 22 Dec 2023

Cited by 2 | Viewed by 1927

Abstract

Dry cutting is an effective method to realize the concept of green cutting today. However, in the process of cutting bearing steel, the high temperatures and high pressures produced by the cutting tool and chip under dry friction seriously affect the machining performance [...] Read more.

Dry cutting is an effective method to realize the concept of green cutting today. However, in the process of cutting bearing steel, the high temperatures and high pressures produced by the cutting tool and chip under dry friction seriously affect the machining performance of the tool. Therefore, a bionic microstructure tool based on bionics is proposed to improve the cutting performance and reduce friction by changing the size parameters of the microstructure. On the basis of finite element simulation and cutting tests, the cutting force, surface roughness, and chip shape are used to evaluate the cutting performance. It is found that composite bionic micro-textured tools have a significantly reduced cutting force compared with non-micro-textured tools; composite bionic micro-textured tools lead to a reduction in surface roughness of 10–25%; and composite bionic micro-textured tools are more prone to enhancing the curling and breaking of chips. In addition, with the increase in the microstructure area occupancy, the cutting performance of the tool was also significantly improved. Moreover, it was found that the cutting performance of the tool was improved when the area occupancy of the micro-texture on the front face of the tool was increased. Full article

(This article belongs to the Special Issue Friction and Wear of Cutting Tools and Cutting Tool Materials)

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18 pages, 11343 KiB

Open AccessArticle

Simulation of Microscopic Fracture Behavior in Nanocomposite Ceramic Tool Materials

by Tingting Zhou, Lingpeng Meng, Mingdong Yi and Chonghai Xu

Lubricants 2023, 11(11), 489; https://doi.org/10.3390/lubricants11110489 - 11 Nov 2023

Viewed by 1603

Abstract

In this paper, the microstructures of nanocomposite ceramic tool materials are represented through Voronoi tessellation. A cohesive element model is established to perform the crack propagation simulation by introducing cohesive elements with fracture criteria into microstructure models. Both intergranular and transgranular cracking are [...] Read more.

In this paper, the microstructures of nanocomposite ceramic tool materials are represented through Voronoi tessellation. A cohesive element model is established to perform the crack propagation simulation by introducing cohesive elements with fracture criteria into microstructure models. Both intergranular and transgranular cracking are considered in this work. The influences of nanoparticle size, microstructure type, nanoparticle volume content and interface fracture energy are analyzed, respectively. The simulation results show that the nanoparticles have changed the fracture pattern from intergranular mode in single-phase materials to intergranular–transgranular–mixed mode. It is mainly the nanoparticles along grain boundaries that have an impact on the fracture pattern change in nanocomposite ceramic tool materials. Microstructures with smaller nanoparticles, in which there are more nanoparticles dispersed along matrix grain boundaries, have higher fracture toughness. Microstructures with a nanoparticle volume content of 15% have the most obvious transgranular fracture phenomenon and the highest critical fracture energy release rate. A strong interface is useful for enhancing the fracture toughness of nanocomposite ceramic tool materials. Full article

(This article belongs to the Special Issue Friction and Wear of Cutting Tools and Cutting Tool Materials)

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19 pages, 24653 KiB

Open AccessArticle

The Study of Tool Wear Mechanism Considering the Tool–Chip Interface Temperature during Milling of Aluminum Alloy

by Xinxin Meng, Youxi Lin, Shaowei Mi and Pengyu Zhang

Lubricants 2023, 11(11), 471; https://doi.org/10.3390/lubricants11110471 - 2 Nov 2023

Cited by 1 | Viewed by 1678

Abstract

ADC12 aluminum alloy has been widely used in the aerospace, ship, and automotive fields because of its high specific strength, excellent die-casting performance, and wear resistance. Adhesion wear is the main wear mechanism of high-speed milling ADC12 aluminum alloy. The most important factor [...] Read more.

ADC12 aluminum alloy has been widely used in the aerospace, ship, and automotive fields because of its high specific strength, excellent die-casting performance, and wear resistance. Adhesion wear is the main wear mechanism of high-speed milling ADC12 aluminum alloy. The most important factor affecting adhesion wear is the tool–chip interface friction, which is directly manifested in the tool–chip interface temperature. Therefore, the temperature variation during the milling of aluminum alloy is analyzed using a temperature field model and infrared temperature measurement technology. Then, the tool wear morphology and the tool wear land width are observed using a scanning electron microscope. Finally, the tool wear mechanism considering the tool–chip interface temperature is discussed. The tool–chip interface temperature is related to the friction angle, tool–chip contact length, and friction force at the rake face, which increases first and then decreases as the cutting speed and feed rate increase. During the formation of the adhesive layer, the tool–chip interface temperature increases, the change rate of the cutting force and the tool wear rate increase, and adhesion, oxidation, and abrasive and delamination wear are generated on the tool surface. With the increase in temperature, the tool wear rate increases, the molten adhesive layer on the tool surface is accompanied by crack propagation, and adhesion wear, oxidation wear, and abrasive wear occur on the tool surface. Full article

(This article belongs to the Special Issue Friction and Wear of Cutting Tools and Cutting Tool Materials)

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12 pages, 12900 KiB

Open AccessArticle

An Experimental Study on Ultrasonic Vibration-Assisted Turning of Aluminum Alloy 6061 with Vegetable Oil-Based Nanofluid Minimum Quantity Lubrication

by Guoliang Liu, Jin Wang, Jintao Zheng, Min Ji and Xiangyu Wang

Lubricants 2023, 11(11), 470; https://doi.org/10.3390/lubricants11110470 - 2 Nov 2023

Viewed by 1770

Abstract

Minimum quantity lubrication (MQL) is a potential technology for reducing the consumption of cutting fluids in machining processes. However, there is a need for further improvement in its lubrication and cooling properties. Nanofluid MQL (NMQL) and ultrasonic vibration-assisted machining are both effective methods [...] Read more.

Minimum quantity lubrication (MQL) is a potential technology for reducing the consumption of cutting fluids in machining processes. However, there is a need for further improvement in its lubrication and cooling properties. Nanofluid MQL (NMQL) and ultrasonic vibration-assisted machining are both effective methods of enhancing MQL. To achieve an optimal result, this work presents a new method of combining nanofluid MQL with ultrasonic vibration assistance in a turning process. Comparative experimental studies were conducted for two types of turning processes of aluminum alloy 6061, including conventional turning (CT) and ultrasonic vibration-assisted turning (UVAT). For each turning process, five types of lubricating methods were applied, including dry, MQL, nanofluid MQL with graphene nanosheets (GN-MQL), nanofluid MQL with diamond nanoparticles (DN-MQL), and nanofluid MQL with a diamond/graphene hybrid (GN+DN-MQL). A specific cutting energy and areal surface roughness were adopted to evaluate the machinability. The results show that the new method can further improve the machining performance by reducing the specific cutting energy and areal surface roughness, compared with the NMQL turning process and UVAT process. The diamond nanoparticles are easy to embed on the workpiece surface under the UVAT process, which can increase the specific cutting energy and Sa as compared to the MQL method. The graphene nanosheets can produce the interlayer shear effect and be squeezed into the workpiece, thus reducing the specific cutting energy. The results provide a new way for the development of eco-friendly machining. Full article

(This article belongs to the Special Issue Friction and Wear of Cutting Tools and Cutting Tool Materials)

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14 pages, 47483 KiB

Open AccessArticle

Measurement and Prediction of Sawing Characteristics Using Dental Reciprocating Saws: A Pilot Study on Fresh Bovine Scapula

by Dedong Yu, Fan Zou, Wenran Zhang, Qinglong An and Ping Nie

Lubricants 2023, 11(10), 441; https://doi.org/10.3390/lubricants11100441 - 12 Oct 2023

Viewed by 1420

Abstract

Bone sawing is one of the most common operations during traditional dental and cranio-maxillofacial surgery and training systems based on virtual reality technology. It is necessary to predict and update conditions (including the sawing force, temperature and tool wear) in real time during [...] Read more.

Bone sawing is one of the most common operations during traditional dental and cranio-maxillofacial surgery and training systems based on virtual reality technology. It is necessary to predict and update conditions (including the sawing force, temperature and tool wear) in real time during VR surgical training and surgical simulation. All the specimens used in this study were fresh bovine scapula. The forces and temperatures were measured during the sawing process. Additionally, the thermal conductivity was measured via a laser flash instrument. Response surface methodology (RSM) was adopted to analyze and model the sawing force and sawing temperature. Meanwhile, tool wear was observed using a scanning electron microscope. The regression models of the sawing force and temperature rise under different experimental conditions were acquired. To obtain the minimum force within the recommended parameter ranges of commonly used medical reference parameters for bone sawing, a higher rotational speed combined with a lower feed rate were recommended. When considering the sawing force and temperature rise comprehensively, the rotational speed should not be extremely high (about 13,000 rpm is recommended). Meanwhile, abrasive wear is the main wear mode of saw blades. In order to avoid surgery failure, it is necessary to replace the saw blade in time. The experimental data were confirmed to be scientific and accurate for the predicted models of sawing conditions. To minimize the main cutting force, a feed rate of 40 mm/min combined with a rotational speed of 13,700 rpm is recommended. High cutting temperatures have the potential to cause irreversible tissue damage, so surgeons using dental reciprocating saws need to avoid excessively high-speed gears. Full article

(This article belongs to the Special Issue Friction and Wear of Cutting Tools and Cutting Tool Materials)

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13 pages, 5008 KiB

Open AccessArticle

Research on Wear of Micro-Textured Tools in Turning GH4169 during Spray Cooling

by Jingshu Hu, Jiaxuan Wei, Xinmin Feng and Zhiwei Liu

Lubricants 2023, 11(10), 439; https://doi.org/10.3390/lubricants11100439 - 12 Oct 2023

Viewed by 1394

Abstract

In this study, the wear resistance of micro-textured tools was explored. Micro-textured tools with different morphologies were used in turning GH4169 during spray cooling. The tool wear on the rake face of the different micro-texture morphologies was investigated through simulation and experiments. Firstly, [...] Read more.

In this study, the wear resistance of micro-textured tools was explored. Micro-textured tools with different morphologies were used in turning GH4169 during spray cooling. The tool wear on the rake face of the different micro-texture morphologies was investigated through simulation and experiments. Firstly, based on the existing research on bionics, micro-textures with five different morphologies were designed on the rake face of carbide tools. A simulation model of cutting GH4169 during spray cooling was established, and the tools with designed micro-textures were used in it. The influence of the different micro-texture morphologies on the tool wear was analyzed. Secondly, the designed micro-textured tools with five different morphologies were produced using a femtosecond laser. Cutting experiments were conducted using the micro-textured tools during spray cooling. The wear area of the rake face was measured based on the infinitesimal method, and the optimal morphology with the best anti-wear ability was obtained. This study provides technical support for the design and development of micro-textured tools with an improved cutting performance, and contribute to the promotion and application of micro-textured tools. Full article

(This article belongs to the Special Issue Friction and Wear of Cutting Tools and Cutting Tool Materials)

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15 pages, 7215 KiB

Open AccessArticle

Thermodynamic Analysis Based on the ZL205A Alloy Milling Force Model Study

by Jing Cui, Xingquan Shen, Zhijie Xin, Huihu Lu, Yanhao Shi, Xiaobin Huang and Baoyu Sun

Lubricants 2023, 11(9), 390; https://doi.org/10.3390/lubricants11090390 - 11 Sep 2023

Cited by 1 | Viewed by 1247

Abstract

The ZL205A aluminum alloy is mostly used in automobiles, aircraft, aerospace, and other mechanical components, but now, it focuses on the study of its casting performance, and there is still a lack of research on its cutting performance. In this paper, the milling [...] Read more.

The ZL205A aluminum alloy is mostly used in automobiles, aircraft, aerospace, and other mechanical components, but now, it focuses on the study of its casting performance, and there is still a lack of research on its cutting performance. In this paper, the milling ZL205A aluminum alloy was milled for testing and simulation analysis. The milling test showed that the impact of the axial cutting depth, radial cutting depth, feed, and cutting speed on the milling force was successively reduced. A thermodynamic analysis model is proposed to evaluate the cutting force and tool design in milling. The model considers the front angle and friction angle of the tool, in which the friction angle is adjusted by the friction coefficient, the variable is the cutting parameter, the constant is fitted through the milling experiment, and the effectiveness of the model is verified to predict the milling force. The pre-grinding test was carried out before the experiment, and the stability of the test was proved by observing the macroscopic shape of the chip and the wear of the cutting edge. The model comprehensively considers the tool angle and quickly calculates the minimum load on the milling cutter based on the optimal geometric parameters, which can be used to optimize the milling cutter structure and provide a theoretical basis for the preparation of ZL205A aluminum alloy mechanical components. Full article

(This article belongs to the Special Issue Friction and Wear of Cutting Tools and Cutting Tool Materials)

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13 pages, 9008 KiB

Open AccessArticle

Improving the Surface Integrity and Tribological Behavior of a High-Temperature Friction Surface via the Synergy of Laser Cladding and Ultrasonic Burnishing

by Nan Xu, Xiaochen Jiang, Xuehui Shen and Hao Peng

Lubricants 2023, 11(9), 379; https://doi.org/10.3390/lubricants11090379 - 7 Sep 2023

Viewed by 1089

Abstract

Quite a lot of engineering friction components serve at high temperatures, and are thus required to have excellent friction and wear resistance. The said study aims to fabricate high-wear-resistance coating on ordinary low-cost materials, achieving the low-cost manufacturing of some high-end friction components [...] Read more.

Quite a lot of engineering friction components serve at high temperatures, and are thus required to have excellent friction and wear resistance. The said study aims to fabricate high-wear-resistance coating on ordinary low-cost materials, achieving the low-cost manufacturing of some high-end friction components that are usually made with expensive solid alloys. The coating was prepared via laser cladding with a sort of widely used Fe-based self-fluxing alloy powder. The chosen substrate material was forged 42CrMo, which is popular in high-temperature friction engineering applications. In order to achieve the best possible high-temperature friction and wear properties, the prepared coating was turned and then ultrasonic burnished. Three samples, i.e., the substrate sample, the cladded sample without burnishing, and the cladded sample with burnishing, were prepared. For the three samples, the surface characteristics and friction properties at a 200 °C temperature were compared and investigated. According to the results, the cladded sample with burnishing exhibited the best surface finishing and friction behavior. Ultrasonic burnishing after cladding led to a further hardness improvement of 15.24% when compared with the cladded sample without burnishing. Therefore, ultrasonic burnishing is an effective low-cost post-treatment method for a wearable coating serving at a high temperature. Full article

(This article belongs to the Special Issue Friction and Wear of Cutting Tools and Cutting Tool Materials)

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21 pages, 9573 KiB

Open AccessArticle

The Surface Assessment and the Properties of Selected Multilayer Coatings

by Bogdan Warcholinski, Adam Gilewicz and Maria Tarnowska

Lubricants 2023, 11(9), 371; https://doi.org/10.3390/lubricants11090371 - 3 Sep 2023

Cited by 3 | Viewed by 1127

Abstract

The paper presents an evaluation of the surface quality and properties of multilayer coatings, obtained using cathodic arc evaporation, of the same structure, in which the top layer is a CrN chromium nitride layer. The second components of a double-layer module with a [...] Read more.

The paper presents an evaluation of the surface quality and properties of multilayer coatings, obtained using cathodic arc evaporation, of the same structure, in which the top layer is a CrN chromium nitride layer. The second components of a double-layer module with a thickness of 400 nm and a thickness of each layer about 200 nm are two component TiN, Mo₂N systems and three component TiAlN and CrCN systems. In studies using scanning electron microscopy and optical microscopy, the surface density of the macroparticles of the coating and their dimensions were estimated. The largest amount of macroparticles was recorded on the surface of the TiAlN/CrN coatings and the lowest on CrCN/CrN and Mo₂N/CrN coatings. Their adhesion to steel substrates using a scratch test and Rockwell test and wear were also investigated. The results indicated that the melting point of the cathode material directly affected the number and size of the macroparticles on the surface of the growing coating. The number of macroparticles increased with the lowering of the melting point of the cathode material. All the coatings showed good adhesion with the critical load Lc₂, greater than 60 N with a hardness above 20 GPa. The Mo₂N/CrN coating, despite its relatively low critical load compared to the other tested coatings, had the best wear-resistant properties, which was probably due to the Mo₂N → MoO₃ transformation. Full article

(This article belongs to the Special Issue Friction and Wear of Cutting Tools and Cutting Tool Materials)

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20 pages, 9304 KiB

Open AccessArticle

Study on a Novel Strategy for High-Quality Grinding Surface Based on the Coefficient of Friction

by Yang Li, Li Jiao, Yanhou Liu, Yebing Tian, Tianyang Qiu, Tianfeng Zhou, Xibin Wang and Bin Zhao

Lubricants 2023, 11(8), 351; https://doi.org/10.3390/lubricants11080351 - 17 Aug 2023

Viewed by 1262

Abstract

Surface quality has a significant impact on the service life of machine parts. Grinding is often the last process to ensure surface quality and accuracy of material formation. In this study, a high-quality surface was developed by determining the coefficient of friction in [...] Read more.

Surface quality has a significant impact on the service life of machine parts. Grinding is often the last process to ensure surface quality and accuracy of material formation. In this study, a high-quality surface was developed by determining the coefficient of friction in grinding a quartz fiber-reinforced silica ceramic composite. By processing the physical signals in the grinding process, a multi-objective function was established by considering grinding parameters, i.e., surface roughness, coefficient of friction, active energy consumption, and effective grinding time. The weight vector coefficients of the sub-objective functions were optimized through a multi-objective evolutionary algorithm based on the decomposition (MOEA/D) algorithm. The genetic algorithm was used to optimize the process parameters of the multi-objective function, and the optimal range for the coefficient of friction was determined to be 0.197~0.216. The experimental results indicated that when the coefficient of friction tends to 0.197, the distribution distance of the microscopic data points on the surface profile is small and the distribution uniformity is good. When the coefficient of friction tends to 0.216, the surface profile shows a good periodic characteristic. The quality of a grinding surface depends on the uniformity and periodicity of the surface’s topography. The coefficient of friction explained the typical physical characteristics of high-quality grinding surfaces. The multi-objective optimization function was even more important for the subsequent high-quality machining of mechanical parts to provide guidance and reference significance. Full article

(This article belongs to the Special Issue Friction and Wear of Cutting Tools and Cutting Tool Materials)

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21 pages, 4369 KiB

Open AccessArticle

Multi-Objective Optimization Design of Micro-Texture Parameters of Tool for Cutting GH4169 during Spray Cooling

by Xinmin Feng, Xiwen Fan, Jingshu Hu and Jiaxuan Wei

Lubricants 2023, 11(6), 249; https://doi.org/10.3390/lubricants11060249 - 6 Jun 2023

Cited by 3 | Viewed by 1594

Abstract

This study explores the performance of micro-textured tools when cutting GH4169 during spray cooling. First, the morphologies of the micro-textures were selected according to the simulation and experiments. Secondly, cutting experiments were carried out during spray cooling. As appropriate for each experiment, regression [...] Read more.

This study explores the performance of micro-textured tools when cutting GH4169 during spray cooling. First, the morphologies of the micro-textures were selected according to the simulation and experiments. Secondly, cutting experiments were carried out during spray cooling. As appropriate for each experiment, regression models of cutting force, cutting temperature, or tool wear area were established, and variance analysis was conducted. The cutting force, cutting temperature, and tool wear area functions were obtained from the respective regression models. Based on these functions, the micro-texture parameters were optimized using the response surface method with the cutting force, cutting temperature, and rake face wear area as the objectives. Finally, a full factor experiment on the micro-texture parameters was designed using Minitab, and cutting experiments were conducted using micro-textured tools with these parameters. Taking a relatively low cutting force, cutting temperature, and tool wear as the objectives, a genetic algorithm multi-objective optimization model for the micro-texture parameters of the tools was established, and the model was solved using the NSGA-II algorithm to obtain a Pareto solution set and micro-texture parameters with a good, comprehensive cutting performance. The micro-texture morphology and parameters obtained in this study can also be used for cutting other high-temperature alloy materials with similar properties to GH4169. This research method can also be used to optimize micro-textured tools for cutting other materials. Full article

(This article belongs to the Special Issue Friction and Wear of Cutting Tools and Cutting Tool Materials)

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18 pages, 4278 KiB

Open AccessArticle

Analysis of Tool Wear in GH4169 Material Milling Process

by Xueguang Li, Wang Zhang, Liqin Miao and Zhaohuan Pang

Lubricants 2023, 11(6), 245; https://doi.org/10.3390/lubricants11060245 - 1 Jun 2023

Cited by 2 | Viewed by 1324

Abstract

Nickel-based superalloy GH4169 is a material with strong mechanical properties and is difficult to process. In order to reduce tool wear during material processing and improve the workpiece surface processing quality, based on the finite element simulation software DEFORM, the influence of n, [...] Read more.

Nickel-based superalloy GH4169 is a material with strong mechanical properties and is difficult to process. In order to reduce tool wear during material processing and improve the workpiece surface processing quality, based on the finite element simulation software DEFORM, the influence of n, a_p, and f_z parameters on tool wear during carbide tool milling GH4169 was studied, and a simulation of an orthogonal experimental model was established. The prediction model of tool wear was obtained. The ultrasonic vibration milling was compared with ordinary milling, and the improvement degree of different coating materials on carbide tool wear was explored. The results showed that the ultrasonic vibration signal is helpful to reduce tool wear, improve the surface quality of the workpiece, and improve the stability of the milling process. TiAlN/TiN (WC)-composite-coated tools have good cutting performance, help to reduce tool temperature, reduce tool wear, and improve tool life. Full article

(This article belongs to the Special Issue Friction and Wear of Cutting Tools and Cutting Tool Materials)

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15 pages, 9892 KiB

Open AccessArticle

Tool Wear and Surface Integrity of γ-TiAl Cryogenic Coolant Machining at Various Cutting Speed Levels

by Xiangyu Wang, Xiaoxia Zhang, Duo Pan, Jintao Niu, Xiuli Fu and Yang Qiao

Lubricants 2023, 11(6), 238; https://doi.org/10.3390/lubricants11060238 - 27 May 2023

Cited by 8 | Viewed by 1460

Abstract

High-speed machining of γ-TiAl alloy is a significant challenge due to high cutting temperatures. From the perspective of environmental protection and improving tool life, appropriate cooling strategies should be adopted. Compared with dry and conventional flood cooling conditions, the feasibility of machining γ-TiAl [...] Read more.

High-speed machining of γ-TiAl alloy is a significant challenge due to high cutting temperatures. From the perspective of environmental protection and improving tool life, appropriate cooling strategies should be adopted. Compared with dry and conventional flood cooling conditions, the feasibility of machining γ-TiAl in cryogenic LN₂ cooling conditions was discussed. The cutting force, tool wear and its mechanism, and surface roughness, as well as sub-surface morphology characteristics, were studied by combining macro and micro techniques. The results revealed that the wear morphology of the rake and flank face under the three cooling media shows different degrees. The crater wear of the rake face is expanded at high speeds and then progresses into more serve flaking and notching wear. The main wear pattern on the flank face is gradually transformed from adhesive wear to diffusion and oxidation wear at high speeds in dry machining. In the LN₂ condition, the diffusion of workpiece elements and cutting-edge oxidation were restrained. The wear pattern is still mainly adhesive wear. In addition, cryogenic machining shows significant advantages in reducing cutting force, suppressing heat-affected zone, improving surface quality, and inhibiting micro-lamellar deformation. Full article

(This article belongs to the Special Issue Friction and Wear of Cutting Tools and Cutting Tool Materials)

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