TY - JOUR

T1 - Design of tool grinding processes for indexable inserts made of rocks

AU - Wolters, Philipp

AU - Breidenstein, Bernd

AU - Denkena, Berend

AU - Bergmann, Benjamin

N1 - Funding Information: P. Wolters conducted the experiments, analysed the data and wrote the manuscript. He was also responsible for project administration together with B. Breidenstein. B. Breidenstein was responsible for funding acquisition and project supervision. He also reviewed and edited the manuscript in the writing process together with B. Denkena and B. Bergmann.

PY - 2023/1

Y1 - 2023/1

N2 - Using natural rocks as alternative cutting tool material poses a possibility to meet actual environmental, economic and geopolitical challenges. The present state of knowledge, however, is not sufficient to allow a knowledge-based design of the tool grinding process of cutting tools made of rock. For this reason, this study presents an investigation of the significance of the grinding process parameters and grinding tool specifications for the flank face and cutting edge roughness as well as for the cutting edge microgeometry besides an analysis of the scatter of the grinding results in tool grinding of rock inserts. Thus, the study contributes to a knowledge-based design of tool grinding processes of rock tools. In this context, confocal and focus variation microscopes are used besides SEM images to investigate the above mentioned factors in the plunge face grinding of rock inserts from five different rocks. The results identify the axial feed velocity of the plunge face grinding process as a highly significant influence factor for cutting edge roughness and microgeometry, while cutting speed only shows a significant influence on cutting edge microgeometry. Besides that, highly significant influences of the used rock type and the abrasive grain size are identified for all three mentioned factors. Grinding result analyses show a scatter between 0.04 and 25.00 µm depending on the parameter and rock investigated. Additionally, recommendations for the design of the tool grinding process of rock tools are presented deduced from the obtained results.

AB - Using natural rocks as alternative cutting tool material poses a possibility to meet actual environmental, economic and geopolitical challenges. The present state of knowledge, however, is not sufficient to allow a knowledge-based design of the tool grinding process of cutting tools made of rock. For this reason, this study presents an investigation of the significance of the grinding process parameters and grinding tool specifications for the flank face and cutting edge roughness as well as for the cutting edge microgeometry besides an analysis of the scatter of the grinding results in tool grinding of rock inserts. Thus, the study contributes to a knowledge-based design of tool grinding processes of rock tools. In this context, confocal and focus variation microscopes are used besides SEM images to investigate the above mentioned factors in the plunge face grinding of rock inserts from five different rocks. The results identify the axial feed velocity of the plunge face grinding process as a highly significant influence factor for cutting edge roughness and microgeometry, while cutting speed only shows a significant influence on cutting edge microgeometry. Besides that, highly significant influences of the used rock type and the abrasive grain size are identified for all three mentioned factors. Grinding result analyses show a scatter between 0.04 and 25.00 µm depending on the parameter and rock investigated. Additionally, recommendations for the design of the tool grinding process of rock tools are presented deduced from the obtained results.

KW - Alternative cutting materials

KW - Cutting tools

KW - Indexable inserts

KW - Natural rocks

KW - Tool grinding

UR - http://www.scopus.com/inward/record.url?scp=85142470067&partnerID=8YFLogxK

U2 - 10.1007/s00170-022-10557-w

DO - 10.1007/s00170-022-10557-w

M3 - Article

AN - SCOPUS:85142470067

VL - 124

SP - 887

EP - 905

JO - International Journal of Advanced Manufacturing Technology

JF - International Journal of Advanced Manufacturing Technology

SN - 0268-3768

IS - 3-4

ER -