Flank Friction Studies With Carbide Tools Reveal Sublayer Plastic Flow

Abstract

Orthogonal cutting tests with artificial flank-wear lands were performed on steel SAE 1112 as-received (cold-drawn), steel SAE 4135 as-received (cold-drawn), aluminum alloy 6061-T6 (extruded), and alpha-brass as cold-drawn. Forces, workpiece temperature, average tool temperatures, and other pertinent data were taken. Each test was of short duration (approximately 10 revolutions of the workpiece or less) and the tools were reconditioned between each test run. The results show that, for steel SAE 1112, steel SAE 4135, and aluminum alloy 6061-T6, sublayer flow appears to take place when the flank wear-land clearance angle is set to a negative angle of magnitude −1 deg and the land is approximately 0.010 to 0.020 in. long. The condition for sublayer flow is predictable based on the state of plastic deformation and the stress-strain properties, at temperature and at appropriate strain rates for these materials.