Micro-scale investigation on belt finishing cutting mechanisms by scratch tests

Belt finishing is an abrasive process that involves various complicated tribological phenomena. To understand the micro-mechanisms in belt finishing, simulation by scratch tests on AISI 52100 steel alloy was proposed. Firstly, scratching using perfect indenter geometry was performed by simulating the real movements and the cutting conditions of belt finishing. Multi-pass scratch and parallel interacting scratch tests were carried out. The influence of the attack angle and the sliding cycle on the deformation behavior and the overall friction coefficient were systematically studied. It was found that with repeated scratches, material is cutting by the fatigue of the instable wedges. A three-dimensional analytical model was established to determine the relationship between the adhesion friction coefficient and the plastic deformation friction coefficient. It was found that the adhesion effect is more influential at small attack angles than at high attack angles. Secondly, the simulation of belt finishing was made by scratch tests at low and high speed with a real grain. With the same conditions, a grain cut less material than a perfect indenter which could be due to the adhesion phenomenon. At high speed, a single grain produces more scratches on the surface. Flow stresses and plastic deformation are more severe. •With repeated scratches or interacting scratch the material deformation is a predominant cutting.•Obtuse grains of the belt can cut material by the fatigue of instable wedges.•The adhesion contribution is important at small attack angles.•Grains cut less material than a perfect indenter because of the adhesion effect.•In belt finishing, the oscillation of the belt is an important parameter for cutting.