An approach to predict derivative-chip formation in derivative cutting of micro-textured tools

• DOI: 10.1007/s00170-017-1285-y
• Publication Date: 2017-11-07T02:48:37Z
• Authors: Ran Duan; Jianxin Deng; Dongliang Ge; Xing Ai; Yayun Liu; Rong Meng; Jintao Niu; Guijie Wang
• Keywords: 0209 industrial biotechnology; 02 engineering and technology

Derivative cutting of micro-textured tool refers to the additional cutting to the bottom side of the chip with the micro-surface textures on the tool surface. In our previous research, it has been proved that piling up of chip in the microgroove of textures is caused by derivative cutting, resulting in structural function failure of the textured tool face. Hence, derivative-cutting behavior needs to be understood and implemented in models. In this study, an analytical approach for the orthogonal cutting process is developed to determinate derivative-chip formation by predictions of the uncut derivative-chip thickness (UDCT) and minimum uncut derivative-chip thickness (MUDCT) values according to cutting parameters, tool geometry, workpiece material properties, and positional and geometrical parameters of textures. The analytical approach is experimentally validated using a 1045 steel workpiece with the textures of different distances to the main cutting edge on the tool rake face. Subsequently, the responses of the UDCT and MUDCT to cutting speed and texture parameters including its geometry and position are quantified on the basis of the proposed approach. Results show that reasonable enlarging of texture-edge radius and proper increasing of cutting speed both are feasible ways to prevent derivative-cutting from derivative-chip formation.