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Cutting Edge Preparation of Precision Cutting Tools by Applying Micro-Abrasive Jet Machining and Brushing

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Cutting Edge Preparation of Precision Cutting Tools by Applying Micro-Abrasive Jet Machining and Brushing Carlos Julio Cortés Rodríguez Cutting edge preparation of precision cutting tools by applying micro-abrasive jet machining and brushing kassel university press Die vorliegende Arbeit wurde vom Fachbereich Maschinenbau der Universität Kassel als Dissertation zur Erlangung des akademischen Grades eines Doktors der Ingenieurwissenschaften (Dr.-Ing.) angenommen. Erster Gutachter: Prof. Dr.-Ing. Franz Tikal Zweiter Gutachter: Prof. Dr.-Ing. Jens Hesselbach Tag der mündlichen Prüfung 17. April 2009 Bibliografische Information der Deutschen Nationalbibliothek Die Deutsche Nationalbibliothek verzeichnet diese Publikation in der Deutschen Nationalbibliografie; detaillierte bibliografische Daten sind im Internet über http://dnb.d-nb.de abrufbar Zugl.: Kassel, Univ., Diss. 2009 ISBN print: 978-3-89958-712-8 ISBN online: 978-3-89958-713-5 URN: urn:nbn:de:0002-7135 © 2009, kassel university press GmbH, Kassel www.upress.uni-kassel.de Druck und Verarbeitung: Unidruckerei der Universität Kassel Printed in Germany iii Vorwort Die vorliegende Dissertation entstand wÄahrendmeiner Arbeit als Doktorand am Instituts fÄurProduktionstechnik und Logistik der UniversitÄatKassel im Fachgebiet Pro- duktionstechnik und Werkzeugmaschinen. Dem Fachgebietsleiter, Herrn Prof. Dr.-Ing. Franz Tikal, danke ich herzlich fÄur seine UnterstÄutzungund hilfreichen Anregungen, die diese Arbeit ermÄoglichten. Herrn Prof. Dr.-Ing. Jens Hesselbach, danke ich fÄurdie UbernahmeÄ des Korreferates. Den Herren Prof. Dr.-Ing. Eberhard Paucksch und Prof. Dr.-Ing. Wolfgang Klose danke ich fÄurdie Bereitschaft zur Teilnahme an der PrÄufungskommission. Mein Dank gilt darÄuber hinaus dem Kollegium des Fachgebiets, das durch die frucht- baren Discussionen und Anregungen zum Gelingen dieser Arbeit beigetragen hat. Der Universidad Nacional de Colombia danke ich fÄurdie UnterstÄutzungund der Stiftung COLFUTURO fÄurdie ¯nanzielle Hilfe. Der KAAD danke ich fÄurdie GewÄahrung eines Stipendiums Äuber 22 Monate und dem ALBAN Programm danke ich fÄurdie GewÄahrung eines Stipendiums Äuber 18 Monate. Ein besonderer Dank gilt meinen Eltern Luis und Alicia, die meine Ausbildung ermÄoglicht haben und meiner Frau Patricia und meinen Kindern Sebastian und Juliana fÄurdie liebevolle UnterstÄutzungund die mir ihre Geduld und Zeit geschenkt haben. Kassel, im April 2009 Carlos Julio Cort¶esRodr¶³guez iv Abstract For the systemic development of precision cutting tools, it is indispensable to observe four related aspects; the cutting tool material, the coating technology, the macro geometry of the tool and the cutting edge preparation. The present work is focused on the last aspect. In accordance with the speci¯ed requirements of the machining process to achieve the quality characteristics of the workpiece, it is necessary to keep in mind the speci¯cations of the cutting tool and particularly their cutting edge preparation. Therefore, to achieve a cutting edge preparation to satisfy the requirements, in terms of reproducibility, quality, cost and flexibility, the selection and planning of the preparation process has special im- portance. In this work, in ¯rst instance, a reproducible methodology of characterization of the cutting edge preparation was proposed, in terms of micro and meso geometry of the cutting tool, as well as the corresponding required measurement strategy by using a chromatic sensor. For the above-mentioned, concepts of di®erential geometry and fractal geometry were used, together with the existent international norms for surface measure- ment. Considering this characterization of the geometry of the cutting edge, three cutting edge preparation processes for cemented carbide tools were analyzed; micro-abrasive jet machining, brushing-polishing and brushing with abrasive ¯laments. By using design of experiments (DoE) and regression analysis, the influence of the process parameters on the quantity of removed material and on the characteristics of the surface of the cutting tool was observed. Aspects as radius of the cutting edge, notchedness (chipping) of the cutting edge, and microstructuring of the cutting tool surfaces were considered for each process. Additionally, machining experiments to observe the influence of the radius of the cutting edge and the preparation process on the cutting forces and the wear of the cutting tool were carried out. With the obtained information from DoE and regression analysis, as well as of the machining experiments, the considered preparation processes can be evaluated, compared, selected and planned. A planning strategy for cutting edge preparation processes considering the nominal removed area as process time function, and an equation to express the development of the notchedness as function of process time, was proposed. The presented aspects of process planning can be applied to other preparation processes. By using DoE, the variability of the obtained cutting edge radius is analyzed, and experimental models that express the removed area as function of the process parameters for the considered preparation processes, were developed. Considering the results of orthogonal cutting tests, the prepa- ration by means of rounding of the cutting edge has a positive e®ect, compared with sharp edges, in the decrease of the cutting forces and force ratio after that a critical point in the development of the test was reached. Additionally, the tools with rounded cutting edges showed a lower ¯nal flank wear than the sharp edges. Di®erences in flank wear for cutting edges with the same radii but obtained by di®erent preparation processes can be explained by di®erences in notchedness and microstructuring. Likewise, the existence of an optimal radius that causes the lower ¯nal flank wear, is observed. v Kurzfassung FÄureine systematische Entwicklung von PrÄazisionszerspanungswerkzeugen, ist es not- wendig vier zusammenhÄangendeAspekte zu beachten: den Schneidsto®, die Beschich- tungstechnologie, die Makrogeometrie und die SchneidkantenprÄaparation.Die vorliegende Arbeit behandelt den letzten dieser vier Aspekte. Bestimmte Anforderungen an die Zerspanungsverfahren sind notwendig, um die geforderten QualitÄatsmerkmalevon Bau- teilen zu garantieren. Es ist daher erforderlich die Spezi¯kationen der Zerspanungswerk- zeuge zu kennen, insbesondere die SchneidkantenprÄaparation.Hierbei spielt die Auswahl und Planung der SchneidkantenprÄaparationeine wichtige Rolle um den Anforderungen in Hinblick auf Reproduzierbarkeit, QualitÄat,Kosten und FlexibilitÄatzu genÄugen. In dieser Arbeit wird an erster Stelle eine Methode zur Charakterisierung der Schneidkan- tenprÄaparationin Hinblick auf Meso- und Mikrogeometrie vorgeschlagen, welche mit Hilfe entsprechender Messtechnik und basierend auf dem Einsatz eines chromatischen Sensors durchgefÄuhrtwird. FÄurdiese Methode wurden Konzepte der di®erentiellen und frak- talen Geometrie, sowie internationale Normen zur Oberfl¨achenmessung angewendet. Zur vorgeschlagenen Charakterisierung der Geometrie der Schneidkante, wurden drei Schneid- kantenprÄaparationsverfahren von Hartmetallwerkzeugen analysiert: Mikrostrahlen, BÄurs- ten-Polieren und BÄurstenmit abrasiven Filamenten. Mittels statistischer Versuchsplanung (DoE) und der Regressionsanalyse wurde der Einfluss der Prozessparameter auf das Ab- tragsmaterial und auf die Merkmale der Werkzeugoberfl¨achen bestimmt. Weitere Aspekte wie der Schneidkantenradius, Schartigkeit und die Mikrostrukturierung der Span- und Freifl¨ache, wurden fÄurjedes SchneidkantenprÄaparationsverfahren untersucht. ZusÄatzlich wurden Zerspanungsversuche durchgefÄuhrt,um den Einfluss des Schneidkantenradius und der PrÄaparationsverfahren auf die SchnittkrÄafteund den Freifl¨achenverschlei¼ zu be- stimmen. Mit den Ergebnissen der statistischen Versuchsplanung, der Regressionsanalyse sowie der Zerspanungsversuche kÄonnenverschiedene PrÄaparationsverfahren verglichen, ausgewertet, geplant und ausgewÄahltwerden. Eine Planungsstrategie zur Schneidkantenverrundung unter BerÄucksichtigung der Abtragsfl¨ache, der Abtragsrate und eine Gleichung zum Verhalten der Schartigkeit als Funktion der Bearbeitungszeit werden vorgeschlagen. Durch DoE werden die Streuung des erzielten Kantenradius bestimmt und experimentelle Modelle vorgeschlagen, um die Abtragsfl¨ache als einen Parameter bei der PrÄaparationsverfahren mit einzubinden. In Anbetracht der Ergebnisse der Versuche mit Orthogonalprozessen und im Vergleich mit scharfen Kanten hat die Verrundung der Schneidkante einen positiven E®ekt in Bezug auf die Verringerung der SchnittkrÄaftenach dem kritischen Punkt. ZusÄatzlich zeigten die Werkzeuge mit verrundeten Schneidkanten am ende der Versuche einen niedrigeren Freifl¨achenverschlei¼ als solche mit scharfen Kanten. Unterschiede des Freifl¨achenver- schlei¼es bei Kanten mit gleichen Radien aber verschiedenen PrÄaparationsverfahren kÄonnen durch Unterschiede in der Schartigkeit und der Mikrostrukturierung erklÄartwerden. Eben- so wird beobachtet, dass ein optimaler Radius den Freifl¨achenverschlei¼ reduzieren kann. vi Contents Vorwort iii Abstract iv Kurzfassung v Nomenclature xi 1 Introduction 1 2 Problem outline and objectives 3 2.1 Problem de¯nition . 3 2.2 Research objectives . 8 2.3 Methodology . 8 3 Fundamentals 9 3.1 Importance and purposes of the cutting edge preparation . 9 3.2 Cutting edge preparation geometries . 13 3.3 Factors influencing the cutting edge geometry . 15 3.4 Influence of the cutting edge preparation in machining . 16 3.4.1 Size e®ect and micromachining . 17 3.4.2 Chip formation . 22 3.4.3 Forces, strain and stresses
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