Analysis of the Influence of Superfinishing on the Surface Topography of Ground Cemented Carbide Rods

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The industrial relevance of high quality bore holes for parts of the automotive industry rises due to the growing requirements to limit CO2 emissions and therefore the tendency of using elevated pressures for the fuel injection. To fulfil these requirements the bores must have a very high surface quality. If large length-to-diameter (l/d) ratios are necessary, e.g. in machining of fuel injectors, deep hole drilling with single-lip drills (SLD) is mostly used to reach good surface qualities. Due to their asymmetric shape one component force acts as a normal force on the circumferential guiding pads of SLDs. For difficult to machine materials the mechanical loads increase as well. This results in a higher wear of the circumferential guiding pads of SLDs, which leads to reduced surface qualities. Many investigations have dealt with the influences of a cutting edge preparation to increase tool life and process parameters to optimise the productivity. Up to now no research work has dealt with the influences of the surface topography of the circumferential guiding pads on the produced bore quality. Thus, in this paper a superfinishing process is applied on cemented carbide rods as model workpieces with the circumferential shape G of SLDs to examine the influences of e.g. the grain size of the finishing film and the pulley hardness on the surface topography and the material removal at the circumferential surfaces.

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... Some examples include high alloyed steels in deep hole drilling (see Fig. 34(a)). Bathe & Biermann [9] investigated the influence of the surface topography of the circumferential guiding pads on the produced bore quality. A superfinishing process was applied on cemented carbide rods for surface treatment. ...
... Different laser textured patterns before and after tribology tests: (a) dimples and (b) channels produced with nanosecond laser, (c) formation of transfer layers on channels produced using nanosecond laser, (d) formation of nano-ripples on the dimples generated using femtosecond laser [8]. [11] and surface treatment methods for tribological enhancement of the guide pads of single-lip drilling tools (b) [9]. edge corner towards the secondary cutting edge. ...
... This is then followed by the identification of the hypothesis of the benefit that should be 48. Summary diagram of structured cutting tool preparation, evaluation, and implications for workpiece quality and tool performance [6,9,11,19,83,90]. (For interpretation of the references to colour in this figure legend, the reader is referred to the web version of this article.) ...
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In the past few decades, there has been considerable advancement in developing and testing structured and textured cutting tools for different machining operations. This paper not only presents a review of the state-of-the-art in manufacturing processes to structure and texture surfaces of cutting tools for machining applications but also identifies the strengths and weaknesses of utilizing structured or textured rake and flank faces as well as other important functional surfaces of cutting tools. This includes an assessment of the relevant texture geometries and microscale structures and their applicability and/or limitations for the improved chip material flow and contact at the chip-tool interface, reduced forces, dynamic deflections, and friction, improved anti-adhesion and tool wear, and enhanced debris management, lubricant, and coolant utilization. This manuscript includes contributions from many research groups in academia who closely work with industry and the content presented herein is expected to provide an organized and comprehensive narrative on current advances, capabilities, and challenges in developing and implementing optimum texture and structure design on cutting tool surfaces with some guidance for future directions.
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An improvement in the efficiency of the cutting process requires high tool performance. For the tool performance the microscopic cutting edge shape is very important. By preparing the cutting edge the tool performance can be improved due to the reduction of the cutting edge chipping and the creation of a defined stable edge rounding. In this study, the influence of a cutting edge preparation on the deep hole drilling process is investigated. The aim is to increase the feed rate by a specific cutting edge design.