Exploring the effects of cutting edge radius on intermittent turning based on experiment and simulation

IF 6.1 1区工程技术 Q1 ENGINEERING, MECHANICAL

Wear Pub Date : 2025-07-05 DOI:10.1016/j.wear.2025.206235

Lirong Huang , Tongtong Wei , Han Chen , Jijun Yuan , Yumei Liu , Dejin Lv , Xiao Qin , Youwen Yang , Zhiqiang Zhong

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引用次数: 0

Abstract

Intermittent cutting generates mechanical and thermal impacts during the entry and cut-out stages, which adversely affect the tool's operational lifespan. In this study, rounded cutting edges with varying radii were prepared using brush grinding. Under consistent cutting conditions, intermittent turning simulations and experiments were conducted on ductile cast iron QT400-15. The experimental results revealed that as the cutting edge radius (CER) increases, the entry impact force and quasi-static forces in all directions also rise, with the feed force exhibiting the most pronounced increase. Under the test conditions, inserts with a CER of 40 μm demonstrated superior cutting performance. Compared to inserts with a CER of 10 μm, the tool life was extended by 37.5 %, and the surface roughness of the machined surface was reduced by 16.9 %. These improvements are attributed to several key factors, including a notable reduction in maximum tool stress, a slight redistribution of forces on the flank face, and minimal impact on the maximum cutting temperature as indicated by finite element simulation results. These enhancements contribute to increased resistance to chipping and deformation, as well as improved wear resistance of the tool.

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通过实验和仿真，探讨了切削刃半径对间歇车削的影响

在进入和切割阶段，间歇性切削会产生机械和热冲击，这对工具的使用寿命产生不利影响。在本研究中，采用电刷磨削制备了不同半径的圆形切削刃。在一致切削条件下，对球墨铸铁QT400-15进行了间歇车削模拟和试验。实验结果表明，随着切削刃半径（CER）的增大，各方向的入口冲击力和准静力均增大，其中进给力的增大最为明显。在测试条件下，CER为40 μm的刀片具有较好的切削性能。与CER为10 μm的刀片相比，刀具寿命延长了37.5%，加工表面粗糙度降低了16.9%。这些改进归功于几个关键因素，包括最大刀具应力的显着降低，侧翼面上的力稍微重新分布，以及有限元模拟结果表明对最高切削温度的影响最小。这些改进有助于增加抗切屑和变形的能力，以及提高工具的耐磨性。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Wear 工程技术-材料科学：综合

CiteScore

8.80

自引率

8.00%

发文量

280

审稿时长

47 days

期刊介绍： Wear journal is dedicated to the advancement of basic and applied knowledge concerning the nature of wear of materials. Broadly, topics of interest range from development of fundamental understanding of the mechanisms of wear to innovative solutions to practical engineering problems. Authors of experimental studies are expected to comment on the repeatability of the data, and whenever possible, conduct multiple measurements under similar testing conditions. Further, Wear embraces the highest standards of professional ethics, and the detection of matching content, either in written or graphical form, from other publications by the current authors or by others, may result in rejection.