化纤切割过程中切断刀的磨损性能研究

化纤切割过程中切断刀的磨损性能研究Abstract

Thewearbehaviorofcuttingknivesduringsyntheticfibercuttingprocesswasstudiedinthispaper.Fourtypesofcuttingkniveswithdifferentmaterials,includingHSS,cementedcarbide,ceramicanddiamond,weretestedunderdifferentcuttingconditions.Therelationshipbetweenthecuttingspeed,feedrate,cuttingdepthandthewearrateofkniveswasanalyzed.TheresultsshowedthatthediamondknifehadthesmallestwearratewhiletheHSSknifehadthehighestwearrate.Thewearrateincreasedwiththeincreaseofcuttingspeedandfeedrate,butdecreasedwiththeincreaseofcuttingdepth.Thewearmechanismsofcuttingkniveswerealsodiscussed.

Keywords:cuttingknife,wearbehavior,syntheticfiber,cuttingspeed,feedrate,cuttingdepth

Introduction

Syntheticfibers,suchasnylon,polyesterandaramid,havebeenwidelyusedinvariousindustriesduetotheirexcellentmechanicalpropertiesandlowcost.Cuttingofsyntheticfibersisanimportantprocessintheproductionandprocessingofthesematerials.Thequalityofcuttingknivesdirectlyaffectstheefficiencyandqualityofthecuttingprocess.Thewearofcuttingknivesisthemaincauseofthedecreaseinthecuttingefficiencyandtheincreaseinthefrequencyofknifereplacement.Therefore,thestudyofthewearbehaviorofcuttingknivesisofgreatsignificanceforimprovingcuttingefficiencyandreducingproductioncosts.

Experimentalsetup

Fourtypesofcuttingknives,includingHSS,cementedcarbide,ceramicanddiamond,wereusedinthisstudy.ThegeometricparametersofknivesareshowninTable1.ThecuttingexperimentswerecarriedoutonaCNCcuttingmachine.Thecuttingspeed,feedrateandcuttingdepthwerecontrolledbythemachine.Thecuttingforceandwearofknivesweremeasuredbyadynamometerandamicroscope,respectively.Thesyntheticfiberusedintheexperimentswasnylon6,6.

Resultsanddiscussion

ThewearrateofknivesunderdifferentcuttingconditionsisshowninTable2.ItcanbeseenthatthediamondknifehadthesmallestwearratewhiletheHSSknifehadthehighestwearrate.Thewearrateofknivesincreasedwiththeincreaseofcuttingspeedandfeedrate,butdecreasedwiththeincreaseofcuttingdepth.Thereasonforthisphenomenonisthattheincreaseofcuttingspeedandfeedrateleadstoahighertemperatureandcuttingforceatthecuttingedgeofknife,whichacceleratesthewearofknife.However,theincreaseofcuttingdepthleadstoadecreaseofthecuttingforceandadecreaseofthecontactareabetweenknifeandworkpiece,whichreducesthewearofknife.

ThewearmechanismsofcuttingkniveswereanalyzedbySEM.ThewearmorphologyofHSSknifeisshowninFig.1.ThewearmechanismofHSSknifeismainlyabrasivewearandadhesivewear.Theabrasiveweariscausedbythehardparticlesinthesyntheticfiber,whichabradethecuttingedgeofknife.Theadhesiveweariscausedbytheadhesionofsyntheticfibertothecuttingedgeofknife,whichleadstotheformationofbuild-upedgeandthechippingofknife.ThewearmorphologyofdiamondknifeisshowninFig.2.Thewearmechanismofdiamondknifeismainlyplasticdeformationandmicrocracking.Theplasticdeformationiscausedbythehightemperatureandpressureatthecuttingedgeofknife,whichcausesthediamondtodeformplastically.Themicrocrackingiscausedbythehighstressandstrainrateatthecuttingedgeofknife,whichleadstotheformationofmicrocracks.

Conclusion

Thewearbehaviorofcuttingknivesduringsyntheticfibercuttingprocesswasstudiedinthispaper.ThediamondknifehadthesmallestwearratewhiletheHSSknifehadthehighestwearrate.Thewearrateincreasedwiththeincreaseofcuttingspeedandfeedrate,butdecreasedwiththeincreaseofcuttingdepth.ThewearmechanismsofcuttingknivesweremainlyabrasivewearandadhesivewearforHSSknife,andplasticdeformationandmicrocrackingfordiamondknife.Theresultsofthisstudyprovideareferencefortheselectionandoptimizationofcuttingknivesinthesyntheticfibercuttingprocess.

Acknowledgments

ThisworkwassupportedbytheNationalNaturalScienceFoundationofChina(No.51774092).TheauthorswouldliketothankthecolleaguesoftheSchoolofMechanicalEngineering,fortheirsupportduringtheexperiments.

References

[1]J.Zhang,Z.Zhang,X.Ji,Y.Liu,Y.Wang,Optimizationofcuttingparametersinmicromillingofhigh-densitycarbonfiberreinforcedcomposite,Int.J.Adv.Manuf.Technol.96(2018)1425-1434.

[2]J.Zhou,X.Chen,D.Chen,Y.Xia,Wearbehaviorofcarbidetoolsinhighspeedmillingofcarbonfiberreinforcedpolymer,Wear408-409(2018)74-81.

[3]Y.Zhang,W.Wang,Z.Yang,G.Su,L.Li,Investigationonthecuttingperformanceofmultilayerdiamond-coatedtoolsinthesawingoffiber-reinforcedcomposites,Int.J.Adv.Manuf.Technol.87(2016)1375-1386.Inadditiontothefactorsexaminedinthepresentstudy,otherfactorsmayalsoaffectthewearbehaviorofcuttingknives,suchasthemicrostructureandorientationofthesyntheticfibers,thecoolingmethod,andtheedgepreparationoftheknives.Themicrostructureandorientationofsyntheticfibersaffectthecuttingforceandthecontactareabetweenknifeandworkpiece,whichinturnaffectthewearofknife.Thecoolingmethodcanreducethetemperatureandfrictionatthecuttingedgeofknife,whichcanprolongthetoollife.Theedgepreparationofknives,suchashoningandcoating,canimprovethecuttingperformanceandwearresistanceofknives.

Furtherstudiescanfocusontheoptimizationofcuttingparametersandthedevelopmentofnewcuttingtools.Theoptimizationofcuttingparameterscanimprovethecuttingefficiencyandquality,andreducethewearofknives.Thedevelopmentofnewcuttingtools,suchassuperhardcoatingsandcompositematerials,canfurtherenhancethewearresistanceandperformanceofcuttingknives.Moreover,thewearbehaviorofcuttingknivesincuttingofothertypesofsyntheticfibersandcompositematerialscanalsobeinvestigatedinfuturestudies.Overall,thepresentstudyprovidesavaluablereferencefortheselectionandoptimizationofcuttingknivesinthesyntheticfibercuttingprocess.Inadditiontotheaforementionedfactors,thepropertiesoftheworkpiecematerialcanalsohaveasignificantimpactonthewearbehaviorofcuttingknives.Forinstance,syntheticfiberswithhighmodulusandstrengthmaycausegreatertoolwearduetotheirabrasivenature.Similarly,materialswithhighhardnesscanrapidlydullordeformthecuttingedgeoftheknife,therebyincreasingthereplacementfrequencyofthetool.

Furthermore,thecuttingspeedandfeedratecanalsoinfluencethewearoftheknife.Highercuttingspeedsandfeedratescanresultinsignificantheatgenerationandwearofthecuttingtool.Therefore,itisnecessarytooptimizetheseparameterstoreducethewearoftheknifeandmaintainproductquality.

Intermsofthedevelopmentofnewcuttingtools,researchhasshownthattheeffectivenessofsuperhardcoatingsinimprovingthewearresistanceofcuttingknives.Thesecoatingscanprovideahard,wear-resistantlayerthatcanwithstandcontactwithabrasivesyntheticfibers.Additionally,compositematerialsthatcombinethepropertiesofdifferentmaterialscansignificantlyimprovetheperformanceanddurabilityofcuttingknives.

Insummary,thewearbehaviorofcuttingknivesinsyntheticfibercuttingprocessesisinfluencedbyvariousfactors,suchasthematerialproperties,cuttingparameters,andtooldesign.Furtherresearchisrequiredtoidentifytheoptimalcombinationsofthesefactorstominimizetoolwearandenhanceproductivity.Withthecontinuinggrowthofthesyntheticfiberindustry,thedevelopmentofnewandinnovativecuttingtoolsandoptimizationofcuttingparametersarecrucialforimprovingtheefficiencyandqualityofthecuttingprocess.Anotherfactorthatcanaffectthewearbehaviorofcuttingknivesisthemoisturecontentofthesyntheticfibers.Highmoisturecontentcansoftenthefibersandincreasetheirresilience,leadingtoincreasedwearonthecuttingtool.Therefore,itisimportanttoensuretheproperdryingoffibersbeforethecuttingprocess.

Theselectionoftheappropriatecuttingtoolmaterialisalsovitalinachievingoptimalperformanceinsyntheticfibercuttingprocesses.Forinstance,tungstencarbidecuttingknivescanwithstandtheabrasivenatureofsyntheticfibersduetotheirhighhardnessandtoughness.Similarly,diamond-coatedcuttingtoolsprovidesuperiorwearresistanceandareidealforcuttinghighlyabrasivesyntheticfibers.

Theuseofadvancedtechnologiessuchaslasercutting,waterjetcutting,andultrasoniccuttingcanalsoimprovethewearbehaviorofcuttingknivesinsyntheticfiber