Nowakowski Lukasz, Bronis Mateusz, Blasiak Slawomir, Skrzyniarz Michal
Department of Machine Design and Manufacturing Engineering, Kielce University of Technology, al. Tysiaclecia Panstwa Polskiego 7, 25-314 Kielce, Poland.
Materials (Basel). 2025 Jan 4;18(1):189. doi: 10.3390/ma18010189.
The minimum cutting thickness is a key value in machining processes, as below this value the material will only undergo elastic and plastic deformation without chip removal. Existing measurement methods require time-consuming preparation and complicated procedures. This work focuses on the development of a new, simplified method for determining the minimum cutting thickness (h) using a contact profilometer that can be used in industry. The use of the contact measurement method has made it possible to directly determine the value of the h parameter, to determine the length of the characteristic zones of interaction of the tool with the surface of the specimen, and to measure the angle of inclination of the working plane of the specimen. Measurement using a profilometer allows for the obtainment of results with high resolution, which greatly facilitates the identification of zones of tool interaction with the workpiece material during the cutting test and reduces the value of the measurement error. The proposed method simplifies the specimen preparation process by using rectangular specimens positioned on an inclined plane, which allows the depth of the cut to be varied smoothly. This paper presents experimental results and statistical analysis. Tests were carried out on C45 steel, and an ANOVA analysis was carried out to evaluate the effect of the grinding parameters on the h parameter. It was found that the feed rate had the largest effect on h (93%), while cutting speed had a smaller effect. A mathematical model was developed to predict values based on selected technological parameters such as cutting speed and feed per tooth.
最小切削厚度是加工过程中的一个关键值，因为低于该值时材料只会发生弹性和塑性变形而不会产生切屑去除。现有的测量方法需要耗时的准备工作和复杂的程序。这项工作的重点是开发一种新的、简化的方法，使用可在工业中使用的接触式轮廓仪来确定最小切削厚度（h）。使用接触测量方法可以直接确定h参数的值，确定刀具与试样表面相互作用的特征区域的长度，并测量试样工作平面的倾斜角度。使用轮廓仪进行测量可以获得高分辨率的结果，这极大地便于在切削试验期间识别刀具与工件材料的相互作用区域，并降低测量误差的值。所提出的方法通过使用放置在倾斜平面上的矩形试样简化了试样制备过程，这使得切削深度能够平滑变化。本文给出了实验结果和统计分析。对C45钢进行了测试，并进行了方差分析以评估磨削参数对h参数的影响。结果发现，进给速度对h的影响最大（93%），而切削速度的影响较小。基于切削速度和每齿进给量等选定的工艺参数开发了一个数学模型来预测值。
