Design and Performance Evaluation of Dual Interchangeable Carbide Inserts for Wheelset Reprofiling
DOI:
https://doi.org/10.31181/rme557Keywords:
Dual Interchangeable Carbide Inserts (DICI), Wheelset Machining, Hardness, Surface Roughness, Cutting ParametersAbstract
The rising cost of carbide tools, which can account for up to 20% of manufacturing expenses, necessitates the development of cost-effective machining solutions. This study investigates the performance of dual interchangeable carbide inserts (DICI) applied in wheelset reprofiling. The research focuses on the relationship between cutting parameters (cutting speed, feed rate, and cutting depth) and surface quality indicators, including hardness and surface roughness. A dfigual interchangeable carbide inserts (DICI) configuration mounted on a specially designed tool holder is proposed to improve tool performance and durability. Experimental results demonstrate that using DICI increases surface hardness by up to 12% compared to conventional inserts while maintaining acceptable surface roughness. Microstructural analysis confirms the formation of compressive stresses and reveals a correlation between cutting regimes and thermal effects in the surface layer. The proposed approach improves machining efficiency, enhances tool life, and provides a cost-effective solution for wheelset maintenance in railway engineering.
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