This work aims to develop an orthogonal cutting model for surface integrity prediction, which incorporates a new constitutive model of Oxygen Free High Conductivity (OFHC) copper. It accounts for the effects of the state of stress on the flow stress evolution up to fracture. Moreover, since surface integrity parameters are sensitive to the microstructure of the work material, this constitutive model highlights also the recrystallization effects on the flow stress. Orthogonal cutting model is validated using experimental designed cutting tests. More accurate predictions were obtained using this new constitutive model comparing to the classical Johnson-Cook model

The authors gratefully acknowledge the support received from IC ARTS and CEA ValducSuperfinishing machining has a particular impact on cutting mechanics, surface integrity and local electrochemical behavior. In fact, material removal during this process induces geometrical, mechanical and micro-structural modifications in the machined surface and sub-surface. However, a conventional 3D cutting process is still complex to study in terms of analytical/numerical modeling and experimental process monitoring. So, researchers are wondering if a less intricate configuration such as orthogonal cutting would be able to provide information about surface integrity as close as possible to that one generated by a 3D cutting process. For that reason, in the present paper, two different machining configurations were compared: face turning and orthogonal cutting. The work material is oxygen free high conductivity copper (OFHC) and the cutting tools are uncoated cemented carbide. The research work was performed in three steps. In the first step, the process mechanics of superfinishing machining of OFHC copper was performed. In the second step, the surface integrity and the chemical behavior of the machined samples were analyzed. Finally, in the third step, correlations between input parameters and output measures were conducted using statistical techniques. Results show that when applying low ratios between the uncut chip thickness and the cutting edge radius, the surface integrity and cutting energy are highly affected by the ploughing phenomenon. Otherwise, the most relevant cutting parameter is the feed. In order to compare face turning with orthogonal cutting, a new geometrical parameter was introduced, which has a strong effect in the electrochemical behavior of the machined surface

The contact between the tool and the workpiece/chip in metal cutting is complex, resulting in high local temperatures and stresses, which may cause severe tool wear and failure. Developments in cryogenic-assisted machining have shown an ecological alternative to the classical metal working fluids, besides tool wear reduction during machining difficult-to-cut materials due to the good ability to dissipate the heat generated by this process. The objective of this work is to analyze the tribological conditions and performance of new coatings specially developed for cryogenic-assisted machining in terms of friction coefficient, volume of build-up material (adhesion) to the tool, and tool temperature. The results have shown that the sliding speed and cooling/lubrication strategy are two main factors that affect the friction coefficient and adhesion of Ti–6Al–4V alloy to the pins. These tribological tests should allow us to select the best coating(s) to be used in cutting tools for further tool wear analysis. Moreover, the obtained friction coefficients could be further implemented into metal cutting models to predict the machining outcomes, including the surface integrity of the machined parts and tool wear.

One of the criteria mastering the choice of a cutting tool is its wear resistance. For coated inserts, prior to the coating process, edge preparation method choice will impact their performance. So, a classification based on its impact on wear resistance is needed. Indeed, the flank wear of three coated cemented carbide inserts presenting differently prepared edges (untreated, dragging and magneto-abrasive machining) is explored experimentally. Those inserts are used to face mill the hardened AISI 4140 low alloy steel. Further, by means of the principal component analysis (PCA), correlations between the online measured cutting forces and flank wear behaviour are investigated. In view of this analysis, for each studied case, the statistical law predicting flank wear relying on cutting forces components is established with fair approximation. However, the experimental results have quantitatively shown that edge preparation could be in some cases not beneficial for tool wear resistance of the milling inserts considering either maximal or average flank wear.