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Title: Adhesive bonding of metal cutting tools
Author: Darwish, S. M. H.
ISNI:       0000 0001 3404 9003
Awarding Body: Birmingham University
Current Institution: University of Birmingham
Date of Award: 1986
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The aim of this work is to develop techniques and to optimize the process of bonding of cemented carbide metal cutting inserts. This replaces the common methods of clamping or brazing. The first stage was to-survey and test structural adhesives to select the most promising adhesive for metal cutting applications. This resulted in a choice of toughened epoxy heat cured adhesive. A comparison between bonded and brazed joints, from the damping capacity point of view was made. In this comparison adhesive bonding resulted in, a higher damping capacity when compared with brazing. The bond line thickness proved to be significant in increasing the damping capacity of the bonded joints. A comparison was carried out between the heat flow through bonded and brazed tools, and demonstrated pronounced heat insulation in the bonded tool, which depended mainly both on the thermal conductivity of the adhesive material and the thickness of the bonded layer. The effectiveness of the bond line thickness, from the points of view of thermal conductivity and developed thermal stresses was investigated. This showed that the thinner the bond line the better is the performance of the bonded joint. The effect of coolant on the temperature of the bond line as well as the tool tip was also investigated. Mixing metallic powder with the adhesive material in order to increase the thermal conductivity of bonded tools was investigated. A new apparatus for measuring low thermal conductivity is proposed. Extensive cutting tests were carried out in order to assess the performance of bonded tools with and without coolant, reground tools and bonded tools having copper powder mixed with the adhesive. The assessment of cutting performance when using bonded tools compared with brazed tools showed that not only a better surface finish could be obtained with bonded tools but also far less tool flank wear
Supervisor: Not available Sponsor: Not available
Qualification Name: Thesis (Ph.D.) Qualification Level: Doctoral
EThOS ID:  DOI: Not available