particles which in turn gives good retentionto the hard abrasive particles.
Figure 3 shows mild steel coated with Al-Si-diamond: (A) SEM photograph of coatedarea, (B) EDX analysis on diamondparticle.
WEAR RATE AND DEPTH OF CUTAS FUNCTION OF TIME, CUTTINGSPEED AND LOAD.
wear rate and loss in cutting wheeldiameter were plotted versus time atvarious loads of ,25, 45 and 65 Nrespectively under constant speed of 6.5cmsec
were plotted, figures 4 and 6.Generally, the wear rate increases as thelead increases and reaches maximum value65 N load. this can be interpreted byreferring to the equation used to calculatethe wear rate. Adverse relation betweencontact area and wear rate is shown, as aresult of increase of contact area due todeep cutting. This cause the wear rate todecrease according to eq (1).
W / A
is wear rate,
W is the loss inwheel weight and A
:is the contact area.For further time increment rapid decrease inwear rate was noticed indicating goodperformance at medium to high load 45 and65 N. consequently, the depth of cutincreases as shown in Figure 5. However, atlow load ,25N,
wear rate shows differentbehavior, this may be due to detachment of diamond particles and deposited particles at lowload. It was postulated that the position of abrasives might be changed as the loadincreases . However if the threshold of bondstrength is not exceeded, the bonding materialwill not break. Therefore, abrasives particlestays intact. As a result wear rate decrease anddepth of cut increases .
In the case of wear of stainless steel cuttingwheel coated with Al-Si alloy as bondingagent with diamond as an abrasive.Generally, the wear rate initially increasedas the time increased until it reachedmaximum value depends on operatingcondition (applied load). this fact is due towear of coatings on the very sharp edge of the wheel. It appears that the behavior of wear rate at the cutting edge is the similarfor all loads. This fact can also be explainedas bonding bridge failure . Duringcoating implementation and at the instant of particles impact on the substrate, it isbelieved that the sputtering of particles ismore pronounced at the cutting edgecompare with areas on the substrate.Therefore the bonding bridges on thesubstrate are stronger than bonding bridgeat the tip of cutting edges.As the time and load increase the wearrate decreased due to good adhesion of hardparticles toward the plate area inside formedium, 45 N, to high, 65N, load.Referring to Figure 5 increase of depth of cut at the same period was observed
W E A R R A T E ( m g . c m
load =25 Nload =45 Nload =65 N
Figure 4 wear rater of stainless steel wheelcoated with Al-Si-diamond against timewith three different loads and constant 6.5(cm.sec