Investigation of Machinability and Tool Wear of Polymer Concrete

Abstract

Polymer concrete, also known as mineral casting, is a composite material renowned for its exceptional mechanical properties and durability, and has garnered significant interest in various engineering applications. However, achieving optimal machinability—particularly in terms of thrust forces and tool wear—remains a critical challenge. This study investigates the relationship between processing parameters and machinability characteristics of polymer concrete, with a particular focus on thrust forces, chip formation, and tool wear. Hole drilling tests were carried out using a Quaser-MV 154C CNC 3-axis vertical machining center, and thrust forces were measured online using a Kistler 9257B force dynamometer. HSS and carbide drills were employed in the experiments. The results show that the use of a carbide drill resulted in lower thrust forces, reduced entry and exit damage, and minimal tool wear compared to the HSS drill. Higher thrust forces were observed at low spindle speeds when using the HSS drill. Overall, the findings indicate that drilling polymer concrete requires the use of a carbide drill, high spindle speeds, and a medium feed rate to minimize hole damage and tool wear.