Large Chip Production Mechanism under the Extreme Load Cutting Conditions

There has existed a great deal of theory researches in term of chip production and chip breaking characteristics under conventional cutting and high speed cutting conditions,however,there isn＇t sufficient research on chip formation mechanism as well as its influence on cutting state regarding large workpieces under extreme load cutting.This paper presents a model of large saw-tooth chip through applying finite element simulation method,which gives a profound analysis about the characteristics of the extreme load cutting as well as morphology and removal of the large chip.In the meantime,a calculation formula that gives a quantitative description of the saw-tooth level regarding the large chip is established on the basis of cutting experiments on high temperature and high strength steel2.25Cr-lMo-0.25V.The cutting experiments are carried out by using the scanning electron microscope and super depth of field electron microscope to measure and calculate the large chip produced under different cutting parameters,which can verify the validity of the established model.The calculating results show that the large saw-toothed chip is produced under the squeezing action between workpiece and cutting tools.In the meanwhile,the chip develops a hardened layer where contacts the cutting tool and the saw-tooth of the chip tend to form in transverse direction.This research creates the theoretical model for large chip and performs the cutting experiments under the extreme load cutting condition,as well as analyzes the production mechanism of the large chip in the macro and micro conditions.Therefore,the proposed research could provide theoretical guidance and technical support in improving productivity and cutting technology research.

Characteristics of different rocks cut by helical cutting mechanism

To research the loading charactefistc of rocks with different structures cut by helical cutting mechanism （HCM）, three different structures of rock （hard-soft-hard rock, soft-hard rock and soft-hard-soft rock） were built. And each type model was further divided into three types when the experiments were carried out. To reduce the errors of cutting load caused by manually configured rock in each test, the cutting load of soft rock was taken as a benchmark, and the differences of the cutting load of the different structures of rocks and the soft rock were used to reflect the cutting load change rules of the HCM. The results indicate that, the cutting load of only the HCM top cutting hard rock is larger than that of only the HCM bottom cutting hard rock for dextral HCM, and the cutting load fluctuation is larger, too. However, when the top and the bottom of the HCM cutting hard rock simultaneously, its cutting load is the largest, but the cutting load fluctuation is the least. And the HCM cutting load increment is increased linearly with the increase of rock compressive strength. The HCM cutting load increment is increased exponentially with the increase of hard rock cutting thickness.