Journal
INTERNATIONAL JOURNAL OF MACHINE TOOLS & MANUFACTURE
Volume 89, Issue -, Pages 202-207Publisher
ELSEVIER SCI LTD
DOI: 10.1016/j.ijmachtools.2014.10.012
Keywords
Saw-tooth chip; Chip morphology; Surface integrity; High-speed cutting
Funding
- Project of Shandong Province Higher Educational Science and Technology Program [J13LB02]
- China Postdoctoral Science Foundation [2013M531593]
- Shandong Province Natural Science Foundation [ZR2013EEM022]
- National Natural Science Foundation of China [51425503, 51375272, U1201245]
- Major Science and Technology Program of High-end CNC Machine Tools and Basic Manufacturing Equipment [2012ZX04003-041]
- Outstanding Young Teacher Domestic Visiting Scholar Project for Colleges and Universities in Shandong Province
- Tai Shan Scholar Foundation
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Saw-tooth chip changes from macroscopically continuous ribbon to separated segments with the increase of cutting speed. The aim of this study is to find the correlations between chip morphology and machined surface micro-topography at different chip serration stages encountered in high speed cutting. High strength alloy steel AerMet100 was employed in orthogonal cutting experiments to obtain chips at different serration stages and corresponding machined surfaces. The chips and machined surfaces obtained were then examined with optical microscope (OM), scanning electron microscope (SEM), and white light interferometer (WLI). The result shows that chip serration causes micro-waves on machined surface, which increases machined surface roughness. However, wave amplitudes (surface roughness) at different serration stages are different. The principal factor influencing wave amplitude is the thickness of the sawed segment (tooth) of saw-tooth chip. With cutting parameters in this study, surface roughness contributed by chip serration ranges from 039 mu m to 1.85 mu m. This may bring on serious problems in the case of trying to replace grinding with high-speed cutting in rough machining. Some suggestions have been proposed to control the chip serration-caused surface roughness in high-speed cutting based on the results of the current study. (C) 2014 Elsevier Ltd. All rights reserved.
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