• Optics and Precision Engineering
  • Vol. 32, Issue 14, 2211 (2024)
Jicai KUAI1,2,*, Yunqian DUAN1,2, Xin LI1, Shian LIU1, and Dmitrii Valerievich ARDASHEV3
Author Affiliations
  • 1Henan Polytechnic University, School of Mechanical and Power Engineering, Jiaozuo454003, China
  • 2Henan International Joint Laboratory of Advanced Electronic Packaging Materials Precision Forming, Jiaozuo454003, China
  • 3South Ural State University, Department of Automation Engineering, Chelyabinsk454080, Russia
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    DOI: 10.37188/OPE.20243214.2211 Cite this Article
    Jicai KUAI, Yunqian DUAN, Xin LI, Shian LIU, Dmitrii Valerievich ARDASHEV. Effect of tool wear and variable friction coefficient on cutting force[J]. Optics and Precision Engineering, 2024, 32(14): 2211 Copy Citation Text show less

    Abstract

    Tool wear and friction coefficients have a big impact on the cutting force and surface quality. To study the effect of tool wear and friction coefficients on cutting force, an cutting force model was developed, taking into account tool wear and variable friction coefficients. First, the edge radius for worn tool was looked at. It was shown that the edge radius gets bigger as the tool wears down. Next, the minimum cutting thickness for worn tool was explained. It was thought that the minimum cutting thickness gets bigger as tool wear and edge radius get bigger. Lastly, the cutting of Al alloy was researched by single crystal diamond tool, and compared the variations in cutting force with respect to cutting depth, feed speed, tool edge radius, tool wear width, and constant and variable friction coefficients. It was shown that the normal and tangential cutting forces increase with increasing depth of cut and feed rate. When the edge radius went from 150 nm to 450 nm, the tangential force went up by 1.13 times and the normal force went up by 2.12 times. When the tool wear width went from 0 to 0.55 μm, the tangential force went up by 1 time and the normal force went up by about 7 times, and the constant friction coefficient model has a maximum error in cutting force of 41%, whereas the variable friction coefficient model has a maximum error within 11%. Hence, the cutting model, which accounts for both tool wear and changing friction coefficients, aligns more closely with the real cutting process.
    Fs=τpa1b1sin φ(1)

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    Fr=2Fs=2τpa1b1sin φ(2)

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    Fz=Frcos π4-φ=Fr2cos φ+sin φ(3)

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    Fy=Frsin π4-φ=Fr2cos φ-sin φ(4)

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    Fz=τpa1b11+1B(5)

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    Fy=τpa1b11B-1(6)

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    ξ=hminhw=cos φ-γsin φ=cos γ+Bsin γB(7)

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    hmin=rn1-cos θθφhmin=rn1-cos φ=rn1-11+B2(8)

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    hw=rn1-11+B2Bcos γ+Bsin γ(9)

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    PD¯=hwsin α(10)

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    τ=τp1-xPD¯(11)

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    F1=τ¯bPD¯=0.5τpbPD¯(12)

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    N1=F1μ1=0.5τpbPD¯μ1(13)

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    F1H=0.5τpbhwcot α-1μ1(14)

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    N1V=0.5τpbhw1 +1μ1cot α(15)

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    F2H=F2=τpbVB¯(16)

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    N2V=N2=F2μ1=τpbVB¯μ1(17)

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    dF3=τpbrndθ(18)

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    dN3=τpbrndθμ1(19)

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    dF3H=τpbrnsin θμ1+cos θdθ(20)

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    dN3V=τpbrncos θμ1-sin θdθ(21)

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    F3H=τpbrnsin θ-cos θμ1+1μ1(22)

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    N3V=τpbrnsin θμ1+cos θ-1(23)

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    FT=FZ+F1H+F2H+F3H=τpa1b11+1B+0.5τpbhwcot α-1μ1+τpbVB¯+τpbrnsin θ-cos θμ1+1μ1.(24)

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    FC=Fy+N1V+N2V+N3V=τpa1b11B-1+0.5τpbhw1 +1μ1cot α+τpbVB¯μ1+τpbrnsin θμ1+cos θ-1,(25)

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    rn'=δcos η+cos η-1rn+NB¯sin β2cos η-sin β2(26)

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    VB¯=2NB¯2rn-NB¯12(27)

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    VB¯=NB¯+NB¯2rn-NB¯+NB¯1/2+rn-NB¯tan α+NB¯cot α,(28)

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    VB¯max=rncos γ+rnsin γtan α+rn1-sin γ-NB¯tan α+cot α(29)

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    μp=ρ2-ρ0.5(30)

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    b=rεcos-1 1-1a'+cos-1 1-b'2(31)

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    Jicai KUAI, Yunqian DUAN, Xin LI, Shian LIU, Dmitrii Valerievich ARDASHEV. Effect of tool wear and variable friction coefficient on cutting force[J]. Optics and Precision Engineering, 2024, 32(14): 2211
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