Analysis of the causes of chip accumulation on cutting tools? When cutting materials with cutting tools, chip buildup often occurs, which itself affects the cutting efficiency of the tool. So, how does this chip buildup form.

1、 Causes of chip buildup on PCD cutting tools

In the part near the cutting edge, the downward pressure increases in the tool chip contact area, causing the underlying metal of the chip to embed into the micro uneven peaks and valleys on the front cutting surface. Due to the increase in metal to metal contact, bonding occurs, and this part of the tool chip contact area is called the bonding area. In the bonding zone, a thin layer of metal material will accumulate on the front cutting surface at the bottom layer of the chips, and the metal material of this part of the chips has undergone severe deformation and strengthening at an appropriate cutting temperature. As the chips continue to flow out, under the pushing force of the subsequent cutting flow, this layer of stagnant material slides away from the upper layer of the chips, becoming the foundation of chip accumulation.

Subsequently, a second layer of hysteresis cutting material will form on top of it, accumulating continuously, forming a chip accumulation lump.

2、 Characteristics and impact on cutting processing

1. The hardness is 1.5-2.0 times higher than that of the workpiece material, and it can replace the front cutting surface for cutting. It has the effect of protecting the cutting edge and reducing the wear of the front cutting surface. However, when debris falls off and flows through the tool workpiece contact area, it can cause wear on the back cutting surface of the tool.

2. After the formation of chip accumulation, the working rake angle of the tool increases, which plays a positive role in reducing chip deformation and cutting force.

3. Due to the accumulation of chips protruding from the cutting edge, the actual cutting depth increases, affecting the dimensional accuracy of the workpiece.

4. Chip accumulation can cause a "furrow" phenomenon on the surface of the workpiece, affecting its surface roughness.

5. The fragments of accumulated debris can bond or embed into the surface of the workpiece, causing hard spots that affect the quality of the machined surface of the workpiece.

From the above analysis, it can be seen that chip accumulation affects the efficiency and accuracy of precision machining.

Three measures to prevent debris accumulation

1. Reduce the roughness of the front blade surface.

2. Increase the rake angle of the tool.

3. Reduce the cutting thickness.

4. Use low-speed or high-speed cutting to avoid cutting speeds that are prone to chip buildup.

5. Properly heat treat the workpiece material to increase its hardness and reduce plasticity.

6. Using cutting fluids with good adhesion and hair resistance (such as extreme pressure cutting fluids containing sulfur and chlorine)