Tailored Chip Breaker Development for Polycrystalline Diamond Inserts: FEM-Based Design and Validation
Chip evacuation is a critical issue in metal cutting, especially continuous chips that are generated during the machining of ductile materials. The improper evacuation of these kinds of chips can cause scratching of the machined surface of the workpiece and worsen the resultant surface quality. This...
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| Format: | Article |
| Language: | English |
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MDPI AG
2019-10-01
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| Series: | Applied Sciences |
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| Online Access: | https://www.mdpi.com/2076-3417/9/19/4117 |
| _version_ | 1818037266645254144 |
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| author | Itxaso Cascón Jon Ander Sarasua Ahmed Elkaseer |
| author_facet | Itxaso Cascón Jon Ander Sarasua Ahmed Elkaseer |
| author_sort | Itxaso Cascón |
| collection | DOAJ |
| description | Chip evacuation is a critical issue in metal cutting, especially continuous chips that are generated during the machining of ductile materials. The improper evacuation of these kinds of chips can cause scratching of the machined surface of the workpiece and worsen the resultant surface quality. This scenario can be avoided by using a properly designed chip breaker. Despite their relevance, chip breakers are not in wide-spread use in polycrystalline diamond (PCD) cutting tools. This paper presents a systematic methodology to design chip breakers for PCD turning inserts through finite element modelling. The goal is to evacuate the formed chips from the cutting zone controllably and thus, maintain surface quality. Particularly, different scenarios of the chip formation process and chip curling/evacuation were simulated for different tool designs. Then, the chip breaker was produced by laser ablation. Finally, experimental validation tests were conducted to confirm the ability of this chip breaker to evacuate the chips effectively. The machining results revealed superior performance of the insert with chip breaker in terms of the ability to produce curly chips and high surface quality (Ra = 0.51−0.56 µm) when compared with the insert without chip breaker that produced continuous chips and higher surface roughness (Ra = 0.74−1.61 µm). |
| first_indexed | 2024-12-10T07:24:07Z |
| format | Article |
| id | doaj.art-9b1ee175a5ff47118146b9e3a18b8a41 |
| institution | Directory Open Access Journal |
| issn | 2076-3417 |
| language | English |
| last_indexed | 2024-12-10T07:24:07Z |
| publishDate | 2019-10-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Applied Sciences |
| spelling | doaj.art-9b1ee175a5ff47118146b9e3a18b8a412022-12-22T01:57:45ZengMDPI AGApplied Sciences2076-34172019-10-01919411710.3390/app9194117app9194117Tailored Chip Breaker Development for Polycrystalline Diamond Inserts: FEM-Based Design and ValidationItxaso Cascón0Jon Ander Sarasua1Ahmed Elkaseer2Advanced Manufacturing Technologies Unit, IK4-TEKNIKER, 20600 Eibar, SpainAdvanced Manufacturing Technologies Unit, IK4-TEKNIKER, 20600 Eibar, SpainInstitute for Automation and Applied Informatics, Karlsruhe Institute of Technology, 76344 Karlsruhe, GermanyChip evacuation is a critical issue in metal cutting, especially continuous chips that are generated during the machining of ductile materials. The improper evacuation of these kinds of chips can cause scratching of the machined surface of the workpiece and worsen the resultant surface quality. This scenario can be avoided by using a properly designed chip breaker. Despite their relevance, chip breakers are not in wide-spread use in polycrystalline diamond (PCD) cutting tools. This paper presents a systematic methodology to design chip breakers for PCD turning inserts through finite element modelling. The goal is to evacuate the formed chips from the cutting zone controllably and thus, maintain surface quality. Particularly, different scenarios of the chip formation process and chip curling/evacuation were simulated for different tool designs. Then, the chip breaker was produced by laser ablation. Finally, experimental validation tests were conducted to confirm the ability of this chip breaker to evacuate the chips effectively. The machining results revealed superior performance of the insert with chip breaker in terms of the ability to produce curly chips and high surface quality (Ra = 0.51−0.56 µm) when compared with the insert without chip breaker that produced continuous chips and higher surface roughness (Ra = 0.74−1.61 µm).https://www.mdpi.com/2076-3417/9/19/4117chip breakerfempcd insertmetal cuttingchip evacuationchip formation |
| spellingShingle | Itxaso Cascón Jon Ander Sarasua Ahmed Elkaseer Tailored Chip Breaker Development for Polycrystalline Diamond Inserts: FEM-Based Design and Validation Applied Sciences chip breaker fem pcd insert metal cutting chip evacuation chip formation |
| title | Tailored Chip Breaker Development for Polycrystalline Diamond Inserts: FEM-Based Design and Validation |
| title_full | Tailored Chip Breaker Development for Polycrystalline Diamond Inserts: FEM-Based Design and Validation |
| title_fullStr | Tailored Chip Breaker Development for Polycrystalline Diamond Inserts: FEM-Based Design and Validation |
| title_full_unstemmed | Tailored Chip Breaker Development for Polycrystalline Diamond Inserts: FEM-Based Design and Validation |
| title_short | Tailored Chip Breaker Development for Polycrystalline Diamond Inserts: FEM-Based Design and Validation |
| title_sort | tailored chip breaker development for polycrystalline diamond inserts fem based design and validation |
| topic | chip breaker fem pcd insert metal cutting chip evacuation chip formation |
| url | https://www.mdpi.com/2076-3417/9/19/4117 |
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