Abstract: In order to solve the chip winding problems during aluminum alloy cutting by PCD cutting tool, a chip breaker groove was designed on rake surface of PCD cutting tools. Through the analysis of forces on chip and chip breaking mechanism of chip breaker grooves, the derivation of the cutting geometry relationships and the finite element cutting simulation experiments, five parameters of chip breaker groove of PCD cutting tools were proposed, including rib width, dip angle, anti-chip angle, groove width and rotation angle of anti-chip surface. The calculation formula of rib width and anti-chip angle of chip breaker grooves for PCD cutting tools were established, and the calculation formula of groove width was improved. The ranges both of dip angle and rotation angle of anti-chip surface were determined. Combined with the solving processes of five parameters of chip breaker grooves, a design method of dimension parameters of chip breaker groove for PCD cutting tools was proposed. Chip breaker groove was fabricated on rake surface of PCD cutting tools with laser. Chip breaking effectiveness of the designed chip breaker groove of PCD cutting tools was proved through cutting experiments of aluminum alloy materials. Experimental results show that the designed chip breaker groove of PCD cutting tools may expand the ranges of cutting parameters with good chip breaking effectiveness.

Key words: polycrystalline diamond(PCD) cutting tool, chip, chip breaking, chip breaker groove

摘要： 为解决聚晶金刚石（PCD）刀具在铝合金材料切削过程中的切屑缠绕问题，在PCD刀具的前刀面上设计了断屑槽。通过对切屑受力过程和断屑槽断屑机理的分析、切削几何关系的推导和有限元切削仿真实验，提取了5个PCD刀具断屑槽参数，即棱带宽度、倾角、反屑角、槽宽和反屑面转角。建立了PCD刀具断屑槽棱带宽度和反屑角的计算公式；改进了槽宽的计算公式；确定了倾角和反屑面转角的取值范围。结合5个断屑槽参数的求解过程，提出了PCD刀具断屑槽尺寸参数的设计方法。应用激光在PCD刀具前刀面加工出断屑槽，通过铝合金材料的切削实验对所设计的PCD刀具断屑槽的断屑效果进行验证，实验结果表明，所设计的PCD刀具断屑槽能够扩大刀具断屑的切削用量范围，具有良好的断屑效果。

关键词: 聚晶金刚石刀具, 切屑, 断屑, 断屑槽