Creating Rational Conditions for Turning Surfaces of Dissimilar Structural Materials by Brittle Superhard Cutters

The authors examine the technological problems that arise during machining by turning complex surfaces composed of materials that are dissimilar in their physico-mechanical characteristics. At the same time, composites are considered attractive for high-speed machining due to the chemical inertness to ferrous metals, the absence of surface tempering and possible charging that are typical of the grinding processes used for the same purpose. In this paper, rational conditions for the tools are created for turning surfaces composed of dissimilar structural materials. A method is developed for setting up a brittle cutter to be used for smooth cutting of a discontinuous surface of a workpiece. In this method, penetration and turning are carried out by the peripheral part of the face of the tool at the maximum possible distance from the tip and the cutting edges. The face of the cutting element is given a cycloidal profile, which makes it possible to eliminate the impact load on the tip of the tool and reduce the friction forces of the chips against the face surface. The authors have developed a tool design that damps intermittent cutting loads and provides increased durability of a composite cutter that is most effective for turning surfaces of dissimilar structural materials. The following results are achieved: machining accuracy of no lower than the 7th grade; and roughness of no more than 1.25 μm.

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