Studies on Wear of a Milling Chuck for a Production Line of Specialized Elements Used in Lockstitch Machines

Abstract

The study aims to determine the wear intensity of selected milling chuck assembly surfaces covered with a protective DLC (Diamond Like Carbon) coating, used on the production line for elements of selected lockstitch machines, and to analyze the stress distributions in the object fixed with such a chuck for the characteristic load systems of this object during its processing. A model of the workpiece was developed using the finite element method. The boundary conditions, including the load and the method of clamping the workpiece, resulted from the parameters of the milling process and the geometric configuration of the milling chuck. Stress distributions in the workpiece for specific milling parameters and for various configurations of the milling chuck holding the workpiece are included in the article. The model experimental studies of wear were conducted in the contact zone between two surfaces covered with DLC: one on the element of the milling chuck pressing the workpiece and the other on the eccentric cams of this holder. The obtained wear values and shapes for the worn surfaces are also shown. The wear intensities for the steel plunger fins modelling swivel arm of the holder were by an order higher than those of corresponding steel shaft shoulders modelling eccentric cam of the holder. The linear wear intensities for these mating components may be expressed in terms of a function of average contact pressure and sliding speed in a corresponding contact zone. The indentation of eccentric cam into mating surface of the swivel arm of the holder increased nonlinearly with the enhancement of number of cycles of the eccentric cam.