Tool wear characteristics of interrupted-cutting Zr-based bulk metallic glasses with cemented carbide tool

The tool wear characteristics and mechanisms were investigated during interrupted-cutting Zr-based bulk metallic glass (BMG). The effect of tool wear on the cutting forces, chip morphology, and machined surface quality was also analyzed. The increase in cutting speed significantly affected the transformation of tool wear behavior. The cutting tool failure form was mainly characterized with adhesive wear and edge chipping. The enhancement of cyclic mechanical impact, caused by the increase of cutting speed in interrupted-cutting, was the main reason for the tool wear behavior transition and life reduction. Furthermore, oxidation wear led to serious boundary wear. The tool wear drastically altered the chip morphology, and the free surface serrated feature disappeared, which was replaced by flaky droplets with the increase of cutting speed. Moreover, it also led to various surface defects on the machined surface, among which the plastic side flow showed the most significant impact on surface roughness.