Built-up edge formation mechanisms in orthogonal cutting of wood-plastic composite

ABSTRACT

This project aims to improve the machinability of wood-plastic composites by understanding chip and built-up edge formation, so as to help manufacturers optimize cutting performance and product quality. Chip formation and built-up edge were studied during orthogonal cutting of wood polyethylene composite with cemented carbide cutters under different conditions. During the orthogonal cutting process, segmental, ribbon, and element chips were generated. The cutting depth was found to have a great impact on the types of chips that formed. Additionally, a built-up edge was found during wood-plastic composite machining, with debris only attaching to the tool's rake face due to thermo-mechanical coupling. Such built-up edges hinder cutting stability and surface quality. Furthermore, variations in the accumulation of debris on the built-up edge corresponded to changes in cutting force and temperature. In fact, both cutting force and temperature proved to be inversely related to the rake angle and positively correlated to the cutting speed and depth. Therefore, to achieve better cutting stability and surface quality for wood-plastic composites, a larger rake angle and a reduced cutting depth are recommended because they reduce the accumulation of debris and the formation of built-up edge.

KEYWORDS:

• Machinability
• WPC
• built-up edge
• tool edge
• cutter
• tool surface

Acknowledgements

The authors gratefully acknowledge the considerable support of the CT WOOD at Luleå University of Technology.

Disclosure statement

No potential conflict of interest was reported by the author(s).

Additional information

Funding

This research was supported by the National Natural Science Foundation of China [grant number 31971594]; the Natural Science Foundation of the Jiangsu Higher Education Institutions of China [grant number 21KJB220009]; the Self-Made Experimental and Teaching Instruments of Nanjing Forestry University in 2021 [grant number nlzzyq202101]; the project from Technology Innovation Alliance of Wood/Bamboo Industry [grant number TIAWBI2021-08], and the International Cooperation Joint Laboratory for Production, Education, Research and Application of Ecological Health Care on Home Furnishing.