CN112917242A - Cutting method for prolonging service life of cutter - Google Patents
Cutting method for prolonging service life of cutter Download PDFInfo
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- CN112917242A CN112917242A CN202110168034.1A CN202110168034A CN112917242A CN 112917242 A CN112917242 A CN 112917242A CN 202110168034 A CN202110168034 A CN 202110168034A CN 112917242 A CN112917242 A CN 112917242A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q15/00—Automatic control or regulation of feed movement, cutting velocity or position of tool or work
- B23Q15/007—Automatic control or regulation of feed movement, cutting velocity or position of tool or work while the tool acts upon the workpiece
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Abstract
The invention discloses a cutting method for prolonging the service life of a cutter, and relates to the technical field of high-speed cutting. The method comprises the following steps of firstly, dividing a cutter cutting process into a running-in abrasion stage, a stable abrasion stage and a severe abrasion stage; then, carrying out aggressive cutting at the running-in abrasion stage by cutting parameters which are more than 20% higher than the typical industrial cutting parameters; and then, entering a stable abrasion stage after the running-in abrasion stage is finished, and adjusting the cutting parameters to the typical industrial cutting parameters to continue cutting until the cutter fails. According to the cutting method for prolonging the service life of the cutter, disclosed by the invention, under the condition that the material property of the cutter is not changed, the transfer of beneficial substances in different sources to a friction interface and the reaction of the beneficial substances to form a protective friction film are dynamically promoted by adjusting the cutting parameters in the cutting process, so that the service life of the high-speed cutting cutter made of materials difficult to machine is greatly prolonged on the basis of ensuring the cutting effect, and the research and development cost is saved.
Description
Technical Field
The invention relates to the technical field of high-speed cutting, in particular to a cutting method for prolonging the service life of a cutter.
Background
High alloy steel, high temperature alloy and the like are widely used for high-end equipment due to excellent performance, and meanwhile, the materials are widely used for saving precious metal elements by using a laser cladding repair technology. These materials and their laser cladding layers are typically difficult to process materials due to one or more of high strength, high hardness, high wear resistance, severe work hardening, low thermal conductivity, high chemical activity, and the like. The high thermal coupling field of high-speed cutting difficult-to-machine materials can bring extremely complex tribology phenomena, and not only can directly damage expensive high-performance cutters, but also can influence the workpiece quality, failure monitoring, machine tool maintenance, production efficiency and manpower expenditure in the manufacturing process, and greatly increase the comprehensive manufacturing cost.
Disclosure of Invention
In view of the above, the invention discloses a cutting method for prolonging the service life of a tool, which dynamically promotes beneficial substances in different sources to transfer to a friction interface and react to form a protective friction film by adjusting cutting parameters in a cutting process under the condition of not changing the material properties of the tool, thereby greatly prolonging the service life of a high-speed cutting tool made of difficult-to-machine materials on the basis of ensuring the cutting effect and saving the research and development cost.
A cutting method for extending the life of a tool according to the object of the present invention comprises the steps of:
the method comprises the following steps: the cutting process of the tool is divided into a running-in abrasion stage, a stable abrasion stage and a severe abrasion stage according to the abrasion loss and the abrasion rate of the tool.
Step two: aggressive cutting is performed at run-in wear stages with cutting parameters above 20% above typical industrial cutting parameters.
Step three: and entering a stable abrasion stage after the running-in abrasion stage is finished, and adjusting the cutting parameters to typical industrial cutting parameters to continue cutting until the cutter is invalid.
Preferably, in the third step, the machining efficiency of the workpiece and the machining cost are considered, if the machining efficiency of the workpiece needs to be kept unchanged, the cutting parameters are kept unchanged until the cutter fails; if the service life of the cutter needs to be prolonged continuously, when the stable abrasion stage is carried out by 40% -60%, the cutting parameters are reduced to be more than 10% lower than the typical industrial cutting parameters again, and cutting is carried out continuously until the cutter fails.
Preferably, the cutting parameters are behavior parameters which influence a thermodynamic system of a cutting process and thus influence the generation rate, composition, structure and performance of the self-organization friction film, and mainly comprise cutting speed, feed amount and back-cut amount.
Compared with the prior art, the cutting method for prolonging the service life of the cutter disclosed by the invention has the advantages that:
(1) the invention can dynamically promote the beneficial substances in different sources to transfer to a friction interface and react to form a protective friction film by optimizing and designing the cutting parameters in the cutting process under the condition of not changing the material properties of the cutter, greatly prolongs the service life of the high-speed cutting cutter made of difficult-to-machine materials on the basis of ensuring the cutting effect, and saves the research and development cost.
(2) The cutting method disclosed by the invention is suitable for wet cutting machining, dry cutting machining, coated cutters and uncoated cutters, and has a wide application range.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below.
FIG. 1 is a tool wear curve for a coated tool DA718 cutting Inconel.
Fig. 2 is a tool wear curve for cutting D2 steel with an uncoated ceramic tool.
Detailed Description
The following provides a brief description of embodiments of the present invention with reference to the accompanying drawings. It is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all embodiments, and all other embodiments obtained by those skilled in the art based on the embodiments of the present invention without any inventive work belong to the protection scope of the present invention.
The invention discloses a cutting method for prolonging the service life of a cutter, which comprises the following steps:
the method comprises the following steps: the cutting process of the tool is divided into a running-in abrasion stage, a stable abrasion stage and a severe abrasion stage according to the abrasion loss and the abrasion rate of the tool.
Step two: and in the running-in abrasion stage, the cutting parameters which are more than 20 percent higher than the typical industrial cutting parameters are used for carrying out aggressive cutting, thereby accelerating the triggering of self-organization behaviors and promoting the stable and dynamic regeneration of the protective friction film. The cutting parameters are behavior parameters which affect a cutting thermodynamic system in a cutting process and further affect the generation rate, components, structure and performance of the self-organization friction film, and mainly comprise cutting speed, feed amount, back-cut amount and the like. Typical industrial cutting parameters refer to cutting parameters commonly adopted by enterprises in the industrial processing of the corresponding parts at the present stage. Therefore, in the adjustment, cutting parameters such as cutting speed, feed amount, and back bite amount are mainly adjusted to be 20% or more higher than typical industrial cutting parameters.
Step three: and entering a stable abrasion stage after the running-in abrasion stage is finished, and adjusting the cutting parameters to typical industrial cutting parameters to continue cutting. Meanwhile, combining the processing efficiency and the processing cost of the workpiece, if the processing efficiency of the workpiece needs to be kept unchanged, keeping the cutting parameters unchanged until the cutter fails; if the service life of the cutter needs to be prolonged continuously, when the stable abrasion stage is carried out by 40% -60%, the cutting parameters are reduced to be more than 10% lower than the typical industrial cutting parameters again, and cutting is carried out continuously to prolong the stable cutting stage, so that the abrasion is further reduced under the condition of ensuring the generation of a friction film, the service life of the cutter is further prolonged, and a new stable period is entered until the cutter fails. In the process, on the premise of ensuring the continuous regeneration of the protective self-organization friction film, the accumulation of excessive mechanical damage and thermal damage is avoided, so that the purpose of further prolonging the service life of the cutter is achieved, and meanwhile, the processing efficiency can be ensured or optimized in the process.
Cutting experiments will be performed below with coated and uncoated tools, respectively, using the above-described cutting method, and the optimization of the method during cutting will be analyzed.
Example 1
The Inconel 718 nickel-chromium alloy is cut by using a TiAlCrSiYN/TiAlCrN coating hard alloy cutter under the condition of using a cutting fluid. Firstly, cutting at a running-in abrasion stage by adopting a cutting speed 50% higher than a typical industrial cutting speed; then in the stable abrasion stage, the cutting speed is reduced to the typical industrial cutting speed, 5% of the stable running-in stage length is cut, the total cutting length is called as a sampling length, and the surface of the cutter is analyzed by an X-ray photoelectric spectrometer at this moment. Cutting is then performed at typical industrial cutting speeds until the end of tool life, and tool life is recorded, with a corresponding tool wear curve being made.
The control experiment was as follows:
cutting at a typical industrial cutting speed until the service life of the cutter is over, recording the service life of the cutter, making a corresponding wear curve, and analyzing the surface of the cutter by using an X-ray photoelectric spectrometer when the cutting length reaches a sampling length.
Cutting at a speed 50% higher than the typical industrial cutting speed until the service life of the cutter is over, recording the service life of the cutter, making a corresponding wear curve, and analyzing the surface of the cutter by using an X-ray photoelectric spectrometer when the cutting length reaches a sampling length.
As shown in fig. 1, according to the cutting method of the present invention, tool life was increased by 24% compared to typical industrial cutting speed cutting, and tool life was increased by 71% compared to 50% compared to typical industrial cutting speed cutting.
The characterization of the thermal protective/lubricating friction film is shown in Table 1, the surface of the cutting tool with the cutting length reaching the sampling length is subjected to X-ray photoelectron spectroscopy analysis, and a large number of thermal protective/lubricating friction films Alx-Oy and Crx-Oy are rapidly generated by the cutting tool in the cutting process in the running-in abrasion stage. The cutting method of the invention generates two cutting methods with the total amount of the thermal protective/lubricating friction film Alx-Oy and Crx-Oy higher than that of the comparison. During wet cutting, the formation of a number of metastable phases (i.e., tribofilms) on the tool surface has a variety of protective effects on the tool surface: 1) the low thermal conductivity compound inhibits heat from entering the tool and leaving the cutting zone with the chip; 2) the cutting fluid has an in-situ lubricating effect on the cutting process; 3) meanwhile, in the process of forming the compound, heat generated in the cutting process is consumed, and thermal shock to the cutter in the cutting process is reduced. The large amount of protective friction films improve the thermal protection and in-situ lubrication performance of the surface of the cutter, and the protective friction films continuously and jointly act with the newly generated protective friction films to protect the surface of the cutter after the cutting speed is adjusted.
TABLE 1 tool surface X-ray photoelectron spectroscopy data when cutting length reaches sampling length
Example 2
The high-carbon high-chromium steel AISI D2 is cut by using an uncoated ceramic cutter under the condition of not using cutting fluid.
Cutting at a cutting speed 20% higher than a typical industrial cutting speed in the cutting process at the running-in abrasion stage, cutting at a stable abrasion stage after the running-in abrasion stage at the typical industrial cutting speed, cutting at a stable abrasion stage length less than 5%, analyzing the surface of the cutter by using an X-ray photoelectric energy spectrometer, and at the moment, the total cutting length is called as a sampling length. The process of cutting around 40% in the steady wear phase to the end of the tool life cuts at a cutting speed 20% lower than the typical industrial cutting speed until the end of the tool life and records the tool life with a corresponding tool wear curve.
To facilitate the demonstration of the specific impact of the invention on tool life, the following control experiments were set up:
cutting at a typical industrial cutting speed until the service life of the cutter is over, recording the service life of the cutter, making a corresponding wear curve, and analyzing the surface of the cutter by using an X-ray photoelectric spectrometer when the cutting length reaches a sampling length.
Cutting at a cutting speed 20% higher than the typical industrial cutting speed until the end of the service life of the cutter, recording the service life of the cutter, making a corresponding wear curve, and analyzing the surface of the cutter by using an X-ray photoelectric spectrometer when the cutting length reaches a sampling length.
Cutting at a cutting speed 20% lower than the typical industrial cutting speed until the end of the service life of the cutter, recording the service life of the cutter, making a corresponding wear curve, and analyzing the surface of the cutter by using an X-ray photoelectric spectrometer when the cutting length reaches a sampling length.
Cutting at a cutting speed 50% lower than the typical industrial cutting speed until the end of the service life of the cutter, recording the service life of the cutter, making a corresponding wear curve, and analyzing the surface of the cutter by using an X-ray photoelectric spectrometer when the cutting length reaches a sampling length.
The effect of the present invention on tool life is further illustrated below with reference to the accompanying drawings:
the AISI D2 cutter wear of the cutting method disclosed by the patent is shown in FIG. 2, the service life of the cutter is prolonged by 99% compared with the service life of the cutting cutter which is carried out at a typical industrial cutting speed, and the efficiency is unchanged; cutting tool life was extended by 36% compared to 20% for cutting speeds below typical commercial cutting speeds.
The thermal protective/protective tribofilm is characterized as in table 2, and X-ray photoelectron spectroscopy was performed on the tool surface at cutting lengths up to the sample length. As in example 1, during the run-in wear phase, the tool surface of example 2 rapidly developed a large amount of thermal protective/in-situ lubricity tribofilm Crx-Oy, and the total amount of the protective tribofilm Crx-Oy formed was higher than the other four cutting options. In the same way as in embodiment 1, during dry cutting, a large number of metastable phases (i.e. tribofilms) formed on the tool surface optimize the cutting process as follows: 1) the low-thermal conductivity compound has a blocking effect on heat entering the cutter, and thermal shock on the cutter is reduced; 2) the compound consumes heat generated by a friction process during formation, and optimizes thermodynamic characteristics during cutting; 3) the compound has certain lubricating property, and the abrasion of the cutter caused by friction is slowed down. In the embodiment, the cutting speed is adjusted for the second time in the middle and later stages of the stable abrasion stage, and the workpiece is cut by using more moderate parameters; on the premise of ensuring the continuous regeneration of the protective self-organization friction film, the accumulation of excessive mechanical damage and thermal damage is avoided, thereby achieving the purpose of further prolonging the service life of the cutter. The cutting speed adjustment in the grinding-in period increases the generation of a protective friction film, the cutting speed adjustment in the stabilization period reduces the thermal damage and the mechanical damage of the surface of the cutter under the condition of ensuring the formation of the protective friction film, the protective friction film can reduce the frictional wear and the thermal shock of the surface of the cutter in the whole cutting process, and the service life of the cutter is greatly prolonged.
TABLE 2 tool surface X-ray photoelectron spectroscopy data after cutting length reaches sampling length
According to the specific embodiments 1 and 2, the cutting method disclosed by the invention can be used for cutting a workpiece, so that the service life of the cutter can be better prolonged under the condition of not changing the material property of the cutter, the manufacturing cost of an enterprise is saved, and meanwhile, the industrial production efficiency can be guaranteed. Therefore, the method has stronger economic benefit and application prospect in the field of high-speed cutting.
The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
Claims (3)
1. A cutting method for extending the life of a tool, comprising the steps of:
the method comprises the following steps: dividing the cutting process of the cutter into a running-in abrasion stage, a stable abrasion stage and a severe abrasion stage according to the abrasion loss and the abrasion rate of the cutter;
step two: carrying out aggressive cutting with cutting parameters more than 20% higher than typical industrial cutting parameters in a running-in abrasion stage;
step three: and entering a stable abrasion stage after the running-in abrasion stage is finished, and adjusting the cutting parameters to typical industrial cutting parameters to continue cutting until the cutter is invalid.
2. The cutting method for prolonging the service life of the cutter as claimed in claim 1, wherein in the third step, considering the processing efficiency of the workpiece and the processing cost, if the processing efficiency of the workpiece at the present stage needs to be kept unchanged, the cutting parameters are kept unchanged until the cutter fails; if the service life of the cutter needs to be further prolonged, when the stable abrasion stage is carried out by 40% -60%, the cutting parameters are reduced to be more than 10% lower than the typical industrial cutting parameters again, and the cutting is continued until the cutter fails.
3. The cutting method for prolonging the service life of the cutter as claimed in claim 2, wherein the cutting parameters are behavior parameters which influence a thermodynamic system of a cutting process so as to influence the generation rate, composition, structure and performance of the self-organizing friction film, and mainly comprise cutting speed, feed amount and back-draught amount.
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| CN202110168034.1A CN112917242A (en) | 2021-02-07 | 2021-02-07 | Cutting method for prolonging service life of cutter |
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