Damage analysis and optimal design of micro-structure milling cutter based on peridynamics

Area of Science:

• Materials Science and Engineering
• Manufacturing Processes
• Tribology

Background:

• H13 die steel presents significant machining challenges due to its high hardness, toughness, and heat resistance, leading to accelerated tool wear and thermal deformation.
• Traditional cutting methods struggle with H13 die steel, necessitating advanced strategies to improve tool performance and longevity.
• Micro-groove design on cutting tools offers a promising avenue for enhancing machining efficiency and tool durability.

Purpose of the Study:

• To optimize the structural parameters of micro-grooves for improving the comprehensive performance of cutting tools used for H13 die steel.
• To analyze the micro-damage mechanisms, specifically micro-cracks, occurring on the cutting tool during the machining process.
• To investigate the relationship between micro-groove design and the mitigation of tool wear and crack propagation.

Main Methods:

• Optimization of micro-groove structural parameters, focusing on groove geometry and placement relative to the cutting edge.
• Numerical analysis of micro-damage using peridynamics simulation.
• Experimental comparison to validate simulation results and assess tool performance enhancements.

Main Results:

• Optimized micro-groove design, characterized by increased distance from the cutting edge and a flattened projection, significantly enhances tool performance.
• Peridynamics simulations revealed that specific milling times (e.g., 3.5×10⁻⁶ s) show rapid displacement increase, highlighting critical periods for tool wear.
• Optimized micro-grooves reduced resultant displacement by approximately 37.06% and effectively controlled near-field crack formation and diffusion on the cutting edge.

Conclusions:

• Strategic optimization of micro-groove structural parameters is crucial for improving the cutting performance of tools machining H13 die steel.
• The study provides a deep understanding of the micro-groove optimization control mechanism and its impact on tool wear and micro-cracking.
• Findings offer valuable insights for the design and manufacturing of high-performance milling tools for difficult-to-process materials like H13 die steel.