In the machining of heat-resistant alloys, the common problem of "boundary wear" leads to the defect of the insert. Here are several ways to reduce boundary wear and improve Ceramic tool life.
1. Depth of cut
As shown in the figure, as the depth of cut increases, the amount of wear, especially the amount of boundary wear, becomes larger. In order to reduce boundary wear and improve tool life, the depth of cut must be controlled.
The table below lists the maximum depth of cut for round-end inserts and the maximum depth of cut for each corner radius. Please refer to these values to determine the depth of the cut.
2. Chamfer
In heat-resistant alloy processing, the larger the lead angle, the smaller the wear performance, and the cutting resistance can be distributed to most of the insert, which can reduce boundary wear, improve tool life, and change surface finish.
In addition, the larger the lead angle, the better the chip handling.
When using SX9, which has excellent chipping resistance, the wear can be reduced by increasing the feed rate, and the machining time can also be shortened.
3. Effective roughing method
When the depth of cut is constant and rough machining is repeated as shown in the figure above, boundary wear occurs in a short period of time, and the tool life is significantly reduced.
In order to suppress boundary wear and prolong ceramic tool life, the following two machining methods are recommended.
① Processing with changing the depth of cut
When the depth of cut is changed during rough machining, the point where boundary wear occurs each time will change, thereby reducing wear.
② Inclined processing
The depth of cut of inclined machining changes continuously, and the wear is distributed to the entire cutting edge. It is the most suitable method for the rough machining of heat-resistant alloys.
4. Effective grooving method
After grooving as shown in the figure above, the corner R corner of the insert is in the work-hardened area of the material being cut.
This kind of grooving will cause small chipping or boundary wear at the corner R of the tool nose as shown in photo L in the lower right corner, and the tool life will be unstable.
A better solution is shown below:
As shown in the figure above, grooving is performed from both sides first, and no edge wear occurs at the corner R of the insert. Then, it is recommended to use an RCGX-shaped blade with excellent strength to remove the remaining middle part.
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