Chip Breaking During Automated Processing by Cutting Hard-to-Work Steels by Integrated Use of Chip Breaking Tools and High-Temperature Embrittlement

Purpose of research is to increase productivity when cutting hard-to-work steels by integrated use of chip breaking tool geometry and cutting modes, which reduce the viscous properties of the chips and the processed material. The article discusses the problems of mechanical processing of parts of oil production equipment at enterprises in Western Siberia. It is presented the main condition for ensuring chip crushing and revealed the problem of low efficiency of existing methods in modern industry, to one degree or another guiding, curling and chip-cutting method.

Methods. Simulation modeling, calculation of chip direction and crushing were performed; effective methods for solving the problem of chip crushing during the machining of parts made of materials with corrosion-resistant, heat-resistant properties were identified; laboratory, persistent tests of the complex method were carried out.

Results of studying the mechanism of chip formation during processing by cutting heat-resistant and corrosionresistant alloys are given here. To solve the problem, we have formulated two tasks that were solved using information taken from the theory of material resistance, tensile diagrams when testing samples of corrosionresistant, heat-resistant materials with high operational properties. A chip breaking exchangeable insert with a variable rake angle is designed and presented. The results and analysis of laboratory test data, in which a plate with chip breaking geometry of the front surface is used, are presented, the operating conditions of effective chip breaking are shown. The conclusions on the solution of the first problem are formulated, it is shown that the determining factor in chip breaking is the physical and mechanical characteristics of the processed material, which vary with different cutting conditions.

Conclusion. The work shows that chip removal from the cutting zone prevents it from entering the cutting edge area, reducing impact loads on it and improving the quality of machining. It is possible to form stress concentrators in the chips, leading to chip self-destruction even when processing viscous heat-resistant alloys. The hypothesis is used that the temperature conditions for the maximum workability of heat-resistant and corrosion-resistant steels and alloys correspond to the conditions of high-temperature embrittlement, with the help of which it is possible to create conditions for effective chip crushing and conditions for maximum workability when cutting heat-resistant steels and alloys.

1. Makarov A.D. Optimizatsiya protsessov rezaniya [Optimization of cutting processes]. Moscow, Mashinostroenie Publ., 1976, 278 p. (In Russ.).

2. Silin S. S. Metod podobiya pri rezanii metallov [Method of similarity when cutting metals]. Moscow, Mashinostroenie Publ., 1979, 152 p. (In Russ.).

3. Grigoriev S. N. Metody povysheniya stoikosti rezhushchego instrumenta [Methods of increasing the resistance of cutting tools]. Moscow, Mashinostroenie Publ., 2011, 368 p. (In Russ.).

4. Poduraev V. N. Rezanie trudnoobrabatyvaemykh materialov [Cutting of hard-to-work materials]. Moscow, Vyssh. shkola Publ., 1974, 587 p. (In Russ.).

5. Adaskin A.M., Butrim V. N., Vereshchaka A.A., Vereshchaka A. S., Kashirtsev V. V. Vliyanie skorosti rezaniya na struzhkobrazovanie pri tochenii zharoprochnykh splavov na osnove khroma i nikelya [Influence of cutting speed on chip formation when turning hightemperature alloys based on chromium and Nickel]. STIN = STIN, 2014, no. 10, pp. 23-27 (In Russ.).

6. Celine Eric, Halbower Löf, Ronnie Altigen. Plastina dlya tokarnoi obrabotki rezaniem i tokarnyi instrument [Plate for lathe machining and lathe tool]. Patent RF, no. 2664348, 2018.

7. Mikhailov S. V., Skvortsov D. S. Smennaya rezhushchaya plastina [Replaceable cutting plate]. Patent RF, no. 2237549, 2004.

8. Vasin S. A., Vasin L. A., Ivanov V. V., Lavit I. M., Khludov S. Ya., Denisov E. P., Denisov I. E. Rezhushchaya plastina [Cutting plate]. Patent RF, no. 2252839, 2005.

9. Madzima Sinia. Rezhushchaya plastina [Cutting plate]. Patent RF, no. 2532612, 2014.

10. Mikhailov S. V., Oleinik A. P. Smennaya rezhushchaya plastina [Replacement plate]. Patent RF, no. 2364475, 2008.

11. Matveev V. S., Bannov K. V., Gradoboev A.V., Kopnova R. D., Nesterenko V. P. Rezhushchaya mnogogrannaya smennaya plastina [Cutting polyhedral replaceable plate]. Patent RF, no. 2327549, 2008.

12. Bobrov V. F. Osnovy teorii rezaniya metallov [Fundamentals of the theory of metal cutting]. Moscow, Mashinostroenie Publ., 1975, 344 p. (In Russ.).

13. Vasin S. A., Vereshchaka A. S., Kushner B. C. Rezanie materialov: Termomekhanicheskii podkhod k sisteme vzaimosvyazei pri rezanii [Cutting materials: Thermomechanical approach to the system of relationships in cutting]. Moscow, MSTU publishing House. N. E. Bauman Publ., 2001, 448 p. (In Russ.).

14. Artamonov E. V., Vasilega D. S., Ostapenko M. S., Schreiner V. A. Rabotosposobnost' instrumentov i fiziko-mekhanicheskie kharakteristiki instrumental'nykh tverdykh splavov i obrabatyvaemykh materialov [Performance of tools and physical and mechanical characteristics of structural hard alloys and processed materials]. Tyumen, Vektor Buk Publ., 2008, 160 p. (In Russ.).

15. Artamonov E. V., Vasil'ev D. V. Determining the optimal cutting speed in turning by composite cutters on the basis of the chip. Russian Engineering Research, 2014, vol. 34, is. 6, pp. 404-405.

16. Trufanov G. G., Artamonov E. V., Vasiliev D. V. Struzhkolo-mayushchaya smennaya rezhushchaya plastina s peremennym perednim uglom [Chip-breaking replaceable cutting plate with variable front angle]. Patent RF, no. 2665858, 2018.

17. Artamonov E. V., Vasiliev D. V., Chernyshov M. O. Sposob opredeleniya optimal'noi skorosti rezaniya [Method of determining the optimal cutting speed]. Patent RF, no. 2658559, 2018.

18. Poletika M. F. Teoriya rezaniya. Mekhanika protsessa rezaniya [Theory of cutting, Mechanics of the cutting process]. Tomsk, 2001 (In Russ.).

19. Mokritskiy B. Ya., Altukhova V. V., Sablin P. A. Povyshenie effektivnosti struzhkoobrazovaniya pri kolesotokarnoi obrabotke [Improving the efficiency of chip formation in wheel-rolling processing]. Problemy mashinostroeniya i avtomatizatsii = Problems of Mechanical Engineering and Automation, 2013, no. 2, pp. 33-38 (In Russ.).

20. Rosenberg J. A. Metody analiticheskogo opredeleniya stepeni deformatsii me-talla struzhki pri rezanii [Analytical Methods for determining the degree of deformation of the metal chips when cutting]. Vestnik mashinostroitelya = Vestnik of Mechanical Engineering, 2001, no.3, pp. 34-38 (In Russ.).