Experimental study and simulation on the chip sticking–welding of the carbide cutter’s rake face

For the study of the tool-chip sticking–welding principle and welding layer formation conditions of the carbide cutter’s rake face, the actual conditions of sticking–welding occurrence during the cutting process were analyzed and the cutting test system which is equivalent to sticking–welding phenomenon was set up. Combined with the finite element simulation technology, sticking–welding phenomenon was analyzed. The effect of stress and temperature field with different cutting parameters on the occurrence of tool-chip sticking–welding and adhesion failure was revealed and adhesion failure location resulting from tool-chip sticking–welding was also obtained. Then aimed at the cutting temperature in the damaged area of the rake face, the mapping model was established using design-expert based on the response surface methodology. The trend of cutting temperature and the state of sticking–welding under the interaction between different parameters were obtained, which provided a theoretical basis for the selection of cutting parameters to avoid sticking–welding.