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Variation of Cutting Forces with Different Cutting Parameters and Tool Wear during Turning of 9442-Nickel-Aluminum Bronze

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Abstract

Nickel-aluminum bronze alloys are prone to tool surface bonding and wear on the tool substrate during the cutting process. The correlation between tool surface bonding morphology, rear face wear, and cutting force is analyzed in terms of the dry turning method for cutting 9442-nickel-aluminum bronze. The rational cutting parameters and the mechanism of tool wear are further discussed. The results indicate that adhesion, oxidation, and abrasive wear occur on the tool surface during turning. At a turning length of 2000 m, tool wear increases with increasing cutting speed and feed. There is a tool wear difference of 2 to 3 μm between adjacent cutting parameters, but the wear is similar at cutting speeds of 140 and 180 m/min. By appropriately reducing the cutting speed and feed rate, it is possible to promote the formation of an adhering layer on the rear face of the tool, thereby reducing overall tool wear. The best cutting results are achieved at a chip speed of 100 m/min and a feed rate of 0.05 mm/rev. However, at higher cutting speeds, there is susceptibility to the “bonding-flaking” phenomenon where material adheres to the tool surface, leading to fluctuations in cutting forces and accelerated tool wear. Higher feed rates result in increased cutting forces, which hinder the formation of an adhering layer on the rear face, causing severe wear on the tool matrix.

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Acknowledgments

The authors sincerely appreciate the financial support from the National Natural Science Foundation of China (Grant No. 52205185 and Grant No. 51975123). Support from the Project on the Integration of Industry, Education and Research of Fujian Province, China (Grant No. 2021Y4004) is highly acknowledged.

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  1. School of Mechanical Engineering and Automation, Fuzhou University, Fuzhou, 350116, China

    Weiqiang Zou, Fuqiang Lai, Dongdong Yi & Youxi Lin

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Zou, W., Lai, F., Yi, D. et al. Variation of Cutting Forces with Different Cutting Parameters and Tool Wear during Turning of 9442-Nickel-Aluminum Bronze. J. of Materi Eng and Perform (2024). https://doi.org/10.1007/s11665-024-09609-x

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