Influence of machining conditions on friction in metal cutting process – A review *

Wpływ warunków obróbki na tarcie w procesie skrawania metali – przegląd literatury

Wit Grzesik, Joel Rech | 09-04-2019

Mechanik nr 04/2019 - Obróbka skrawaniem

ABSTRACT: This paper presents a range of variable machining factors which influence substantially friction directly or by the tool wear developed in the cutting zone. The group of direct factors include the workpiece and cutting tool materials coupled, the cutting/sliding velocity, cooling media supplied to the tool-chip contact zone, modification of the tool contact faces by micro-texturing. Special attention was paid to the tool wear evolution and its pronounced effect on changes of the contact conditions.

KEYWORDS: metal cutting, friction, contact conditions, wear

STRESZCZENIE: Przedstawiono wiele zmiennych czynników procesowych, które istotnie wpływają – bezpośrednio lub pośrednio przez zużycie ostrza – na tarcie występujące w strefie skrawania. Grupa czynników bezpośrednich obejmuje: materiał obrabianego przedmiotu i narzędzia skrawającego, prędkość skrawania/poślizgu, media chłodzące dostarczane do strefy kontaktu oraz modyfikację powierzchni kontaktowych ostrza narzędzia przez mikroteksturyzowanie. Specjalną uwagę zwrócono na ewolucję zużycia narzędzia i jej dominujące oddziaływanie na zmiany warunków kontaktowych.

SŁOWA KLUCZOWE: skrawanie metali, tarcie, warunki kontaktowe, zużycie

Galeria

Fig. 1. Evolution of apparent friction coefficient vs. sliding velocity for various material pairs [5, 6]

Fig. 2. Evolution of macroscopic friction coefficient vs. sliding velocity for a range of steels vs. TiN/WC-Co pin, pin diameter dp = 17 mm, normal load Fn = 1000 N [4]. Symbols: R – standard, CG – coarse grain, GP – globular pearlitic, WB – with band

Fig. 3. Influence of lubrication mode and oil viscosity on friction coefficient: a) full lubricated, b) MQL [8]

Fig. 4. Comparison of cooling supply method on friction coefficient [9]

Fig. 5. Influence of sliding velocity and cooling medium on apparent friction coefficient in the tribo-test of Inconel 718 against TiN/WC-Co pin, dp = 9 mm, Fn = 1000 N [10]

Fig. 6. Characteristic trends in the performance of friction coefficient at very high cutting speeds [15]. Workpiece material: low alloy 42CrMo4 steel, 1 – ap = 0.2 mm; 2 – ap = 0.5 mm (ap – depth of cut)

Fig. 7. Influence of cutting tool coatings on friction coefficient when dry machining 42CrMo4 steel (AISI4140, 300 HB), WC-Co pin, dp = 9 mm, Fn = 1000 N, contact pressure p ≈ 2600 MPa [16]

Fig. 8. Ratio between ball wear area and sample trace depth vs. number of revolutions. Wear tests performed at 800°C [22]

Fig. 9. Schematic illustration of lubrication action for cutting tools with smooth (a) and textured (b) rake face; c) and d) examples of nano-/micro-textures performed on milling inserts [23]

Fig. 10. Changes of adhesion evolution (a) and friction coefficient (b) for textured rake faces from Fig. 9c in aluminium milling [21, 23]

Fig. 11. Friction coefficient evolution of the TiN coated sample under load 200 N (a) and TiN, TiAlN, AlTiN and CrAlN PVD nitride coatings as function of number of cycles after [24, 25]

Fig. 12. Confocal image of worn cutting tool (a) determination of the equivalent rake angle (b) after [26]. 1 – the shape of fresh tool, 2 – the shape of worn tool, 3 – planar equivalent rake face

Fig. 13. Changes of friction coefficient at rake and flank faces after [26]

Fig. 14. Changes of friction coefficient on the rake face with tool wear resulting from variations of feed rate (a), tool nose radius (b) and depth of cut (c) after [27]

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DOI: https://doi.org/10.17814/mechanik.2019.4.33

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