This work presents a systematic and comprehensive investigation of the protective effect of built-up layer (BUL) in dry cutting of stainless steel SUS304. A detailed examination of BUL and built-up edge (BUE) formation conditions, their formation mechanisms, and their protective effect was carried out at different cutting speeds (5–140 m/min), and different feed rates (0.02–0.1 mm/rev). The uncoated cemented carbide tool was used as a cutting tool. The dimensions of BUL/BUE and tool wear were measured by scanning electron microscope (SEM) and laser confocal microscopy (LCM). The protective effect of BUL/BUE was characterized using flank wear progression, as well as crater wear progression, cutting force analysis, and surface roughness analysis. As a result, it was found that BUE forms around the cutting edge at low cutting speeds (5–20 m/min), and BUL, which resembles a water drop, forms on the tool rake face at cutting speeds equal to or above 40 m/min. And a thin layer of flank built-up (FBU) can form on the tool flank face as the cutting speed increases from 40 m/min to 140 m/min. The BUL/BUE formation mechanism was also confirmed. It was revealed that BUL can be considered as a protective layer, which can not only prevent the tool rake face from wear but also decrease the tool flank wear, but BUE can only prevent the crater wear; and to a certain extent, the thin layer of FBU can also work as a protecting layer on the worn tool flank face in dry cutting of SUS304. It was also revealed that the height of BUL plays a very important role in its protective effect. Meanwhile, it was found that BUL and the thin layer of FBU have no or few influences on the amplitude variation of cutting forces and on the surface roughness. These results indicated that BUL can be used to realize the self-protective tool (SPT) in cutting of difficult-to-cut material such as SUS034. In addition, the research also proved that it is necessary to take the influences of BUL, BUE, and FBU formations on tool wear into account in the tool wear model in order to achieve high-precision prediction.

这项工作对不锈钢SUS304的干式切削中堆积层（BUL）的保护作用进行了系统的全面研究。在不同的切削速度（5-140 m / min）和不同的进给速度（0.02-0.1 mm / min）下，对BUL和堆积边缘（BUE）的形成条件，其形成机理及其保护效果进行了详细检查。转速）。将未涂覆的硬质合金刀具用作切削刀具。BUL / BUE的尺寸和工具磨损通过扫描电子显微镜（SEM）和激光共聚焦显微镜（LCM）进行测量。BUL / BUE的保护作用通过侧面磨损进程，月牙洼磨损进程，切削力分析和表面粗糙度分析来表征。结果发现，在低切削速度（5–20 m / min）下，BUE在切削刃周围形成，等于水滴的BUL以等于或大于40 m / min的切削速度在刀具前刀面上形成。随着切削速度从40 m / min增加到140 m / min，在刀具侧面上会形成一层薄的侧面堆积（FBU）。还证实了BUL / BUE的形成机理。结果表明，BUL可以作为保护层，不仅可以防止刀具前刀面的磨损，而且可以减少刀具后刀面的磨损，而BUE只能防止凹坑的磨损。并且在一定程度上，FBU薄层还可以在SUS304的干切削中用作磨损的工具侧面上的保护层。还显示出BUL的高度在其保护作用中起着非常重要的作用。与此同时，已经发现，BUL和FBU的薄层对切削力的幅度变化和表面粗糙度没有或几乎没有影响。这些结果表明，BUL可用于实现难切削材料（例如SUS034）的切削自保护工具（SPT）。此外，研究还证明，在刀具磨损模型中必须考虑到BUL，BUE和FBU构造对刀具磨损的影响，才能实现高精度的预测。