The Preparation Of Micro-texture Tools Through Die-formation Method And The Study On Its Cutting Processes

During the material cutting process,it is a high affinity between the cutting performance and the tool wear.At the same time,the tool wear is affected by the cutting conditions,the tool geometries and the material properties of the workpiece.Therefore,reducing the tool wear during the cutting processes can effectively improve the tool life and improve the processing quality of the workpiece.In recent years,micro-texture tools has proven to play an important role in reducing the tool wear during the cutting processes.However,the existing micro-texture fabrication technology has the problem that its processing efficiency is low and can not realize the mass manufacture.In order to achieve the economical and efficient preparation of micro-texture tools,this study proposes a micro-texture tool preparation method of die-formation to improve the preparation efficiency of micro-texture tool.The prepared micro-texture cemented carbide tool is used for turning titanium alloy and nickel-based alloy after shot blasting,grinding and cutting edge rounding.With its antifriction effect where the micro-texture could improve the tool-chip and tool-workpiece contact states,decrease the cutting temperature and improve the tool life.The study mainly focuses on the design and preparation of the micro-texture,the preparation of the micro-texture tool forming die,and cutting experiments with the micro-textured tool under the dry and self-lubrication conditions.A linear groove array type micro-texture was processed on the surface of YG6 cemented carbide.Besides,friction and wear tests under dry lubrication,based oil lubrication and nano-particle-additive-oil lubrication conditions were carried out using a high-speed reciprocating friction and wear tester.By analyzing the dynamic friction coefficient during experiment processes,the surface wear marks of cemented carbide and steel ball,respectively,it provided a theoretical basis for the design of micro-texture tools.Based on WEDM-LS technology,a micro-texture cemented carbide tool blankforming-die was prepared,including an upper punch,a negative die and a lower punch.Wherein the upper punch,vertical and parallel micro-texture grooves were processed with groove widths of 100?m and 200?m,a groove depth of 100?m,and a distance of 200?m.The micro-texture tool blank was pressed by TPA type press machine,of which the pressure was 14 KN.Then the micro-texture tool blanks were sintered,and the sintering temperature was controlled around 1420 °C.Surface shot blasting,grinding and cutting edge rounding were performed after the sintering processes.Utilizing the CA6140 lathe,the cutting experiments of titanium alloy Ti-6Al-4V and nickel-based superalloy GH4169 under the dry conditions were carried out as well as titanium alloy self-lubrication cutting experiments.After the characterization of the experimental results,the wear mechanism of the rake and flank surfaces of the tool were investigated.The chip shape,shear angle and friction coefficient were analyzed,too.During the dry cutting processes,the vertical type micro-texture tool whose width was 100?m appeared the best cutting performance while the 200?m-width microtexture appeared the better cutting performance during the self-lubricated cutting processes.