Adhesion Behavior Between Cutting Tool And Workpiece And Its Experimental Study In Machining Of Pure Iron

Pure iron is a kind of ferroalloy with carbon content of less than 0.028%.It is widely used in weapon industry,aircraft industry,and electron industry due to its high magnetic permeability,high magnetic induction,and low coercivity.For its high ductility and low hardness,high cutting temperature,large chip deformation and severe adhesion between cutting tool and workpiece would generate during pure iron machining process.Adhesion behavior between cutting tool and workpiece including between rake face and chip,flank face and machined surface may effect cutting tool performance and serve life,as well as machined surface bad integrity.Theoretical analysis of influencing factors and the mechanism in tool-workpiece adhesion process was conducted in this paper.Cutting experiments to explore the tool-workpiece adhesion behavior and its rule under the condition of different cutting speeds,the surface morphology of the tools and the cutting edge radius was carried out.High pressure cooling lubrication was adopted on the purpose of solving severe heat-induced wear of CBN tool and ceramic tool during pure iron machining process,the influence of high pressure cutting fluid on tool-workpiece adhesion behavior was also investigated,and finally suggestion on reducing tool-workpiece adhesion was proposed.Firstly,theoretical analysis of adhesion performance,adhesion formation and development,and mechanics mechanism during metal machining process was conducted.On the basis of adhesion mechanics mechanism and analysis of influence factors of tool-workpiece friction,a comprehensive physical model of influence factors was proposed,influence factors action mechanism were also discussed.Secondly,experiments were conducted taking pure iron as processing material by considering the three influence factors indicted by the physical model,including cutting speed(workpiece dynamic mechanics),tool surface microphotography,and tool edge radius.Adhesion behavior and rules of tool-workpiece were explored by observing and analyzing adhesion morphology of chip underlayer,machined surface,and tool surface obtained during pure iron material machining processing.Finally,pure iron cutting experiments were carried out under high pressure cooling lubrication condition in the view of reducing tool-workpiece friction by considering the performance of CBN tool and ceramic tool in pure iron machining process which show light tool-workpiece adhesion but severe heat-induced tool wear.The adhesion morphologies of chip underlayer,machined surface and cutting tool surface were also analyzed to investigate the effects of high pressure cutting fluid on tool-workpiece adhesion behavior and cutting tool performance.