Determining the conditions for decreasing cutting force and temperature during machining

Abstract

We have developed a new theoretical approach to define the cutting force and temperature during blade and abrasive machining, taking into account the energy intensity of the cutting process, which allowed a scientifically sound approach to controlling the mechanical and heat stresses of machining and establishing conditions for improving quality and productivity. It has been theoretically established that when grinding, the cutting temperature is always higher than during blade processing due to the presence of intense friction of the bond of the grinding wheel with the material being processed. It is shown that it is possible to reduce the cutting temperature during grinding using the multi-pass grinding scheme, as well as high-performance deep grinding schemes with the end face of a circle and a circle with a double-sided conical profile. On this basis, a highly efficient defect-free gear grinding technology was developed using the profile copy method on a modern gear grinding machine of the HOFLER RAPID 1250 model using a special highly porous profile abrasive wheel with a double-sided conical profile with high cutting ability, which provides up to 5 times increase in machining performance compared to the gear grinding scheme break-in method. A technology has also been developed for high-performance deep circular external grinding of cutting multi-blade carbide tools (milling cutters, reamers) with diamond wheels on high-strength metal bonds using the EDM method, which made it possible to increase productivity by a factor from 2 to 3 times and provide high-quality defect-free machining of carbide tools.