The influence of cutting edge sharpness on surface finish in facing with round nosed cutting tools

Polycrystalline Cubic Boron Nitride (PcBN) cutting tools have excellent characteristics, such as a high degree of hardness and low chemical reactivity, so they have the potential to replace the high precision grinding of hardened steel with high precision cutting. However, there are some problems inherent in so-called sintered materials, including low formability and unsteady wear. In order to solve these problems, pulsed laser processing is applied to shape a cutting edge. In this study, first PcBN cutting tools processed by lasers are adopted to the high-precision turning of hardened steel with 58HRC. As the result, these PcBN cutting tools provide a steady cutting state and a smoother finished surface. Second, in order to investigate these advantages of PcBN cutting tools processed by laser, individual requirements of the cutting tool are investigated: edge sharpness, surface quality including micro-defects, surface hardness, and friction coefficient. The results indicate that tools processed by laser have sharper edges and smoother, harder, and lowerfiction surfaces, compared to ground tools. Above all, the increase in surface hardness improves cutting performance because of it provides higher wear resistance.

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Cutting Tool Wear and Mechanisms of Chip Formation During High-Speed Machining of Compacted Graphite Iron

ASME/STLE 2007 International Joint Tribology Conference, Parts A and B ◽

10.1115/ijtc2007-44026 ◽

2007 ◽

Author(s):

Niniza S. P. Dlamini ◽

Iakovos Sigalas ◽

Andreas Koursaris

Keyword(s):

Tool Wear ◽

Surface Finish ◽

Failure Criterion ◽

Cutting Tool ◽

Flank Wear ◽

Cutting Tools ◽

Compacted Graphite Iron ◽

Crater Wear ◽

Compacted Graphite ◽

Cutting Speeds

Cutting tool wear of polycrystalline cubic boron nitride (PcBN) tools was investigated in oblique turning experiments when machining compacted graphite iron at high cutting speeds, with the intention of elucidating the failure mechanisms of the cutting tools and presenting an analysis of the chip formation process. Dry finish turning experiments were conducted in a CNC lathe at cutting speeds in the range of 500–800m/min, at a feed rate of 0.05mm/rev and depth of cut of 0.2mm. Two different tool end-of-life criteria were used: a maximum flank wear scar size of 0.3mm (flank wear failure criterion) or loss of cutting edge due to rapid crater wear to a point where the cutting tool cannot machine with an acceptable surface finish (surface finish criterion). At high cutting speeds, the cutting tools failed prior to reaching the flank wear failure criterion due to rapid crater wear on the rake face of the cutting tools. Chip analysis, using SEM, revealed shear localized chips, with adiabatic shear bands produced in the primary and secondary shear zones.

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Kantenpräparation durch Formschleifprozesse*/Cutting edge preparation by form grinding

wt Werkstattstechnik online ◽

10.37544/1436-4980-2017-06-69 ◽

2017 ◽

Vol 107 (06) ◽

pp. 453-460

Author(s):

E. Prof. Uhlmann ◽

J. Bruckhoff

Keyword(s):

Tool Life ◽

Cutting Tools ◽

Cutting Edge ◽

Grinding Processes ◽

Form Grinding ◽

Cutting Edge Preparation ◽

Edge Preparation

Angesichts steigender Anforderungen an Zerspanwerkzeuge nimmt die Schneidkantenpräparation einen immer größer werdenden Stellenwert ein, da sich so die Standzeit von Zerspanwerkzeugen erhöhen lässt. Die bisher eingesetzten Präparationsverfahren eignen sich meist nur für einfache Verrundungen an der Schneidkante. In umfangreichen Untersuchungen wurde die Eignung von Formschleifprozessen zur Herstellung definierter Schneidkantenmikrogeometrien anhand von Arbeitsergebnissen analysiert.   Due to increasing demands on cutting tools cutting edge preparation has a high priority because it influences the tool life. Current cutting edge preparation processes can only generate simple roundings on the cutting edge. By extensive investigations the suitability of form grinding processes for the production of defined microgeometries on the cutting edge was analysed.

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Analysis a cutting edge geometry influence on circular saw teeth at the process of crosscutting wood

Acta Universitatis Agriculturae et Silviculturae Mendelianae Brunensis ◽

10.11118/actaun200957050177 ◽

2009 ◽

Vol 57 (5) ◽

pp. 177-182 ◽

Cited By ~ 3

Author(s):

Ján Kováč ◽

Milan Mikleš

Keyword(s):

Cutting Tools ◽

Measurement Procedure ◽

Cutting Edge ◽

Production Costs ◽

Cutting Process ◽

Detailed Measurement ◽

Edge Geometry ◽

Circular Saw ◽

Measuring Devices ◽

Circular Saws

Nowadays, the wood cutting process looks like a technological scheme consisting of several connected and relatively inseparable parts. The crosscutting wood is the most widespread in the process of forest exploitation; it is used at tree exploitation, shortening stems and assortment production. The article deals with the influence of the cutting edge geometry of circular saws on the torque and also on the cutting performance at the crosscutting wood therefore there is the influence on the whole cutting process. In the article there is described detailed measurement procedure, used measuring devices and the process of results analysis. Knowledge of wood crosscutting process and choice of suitable cutting conditions and cutting tools will contribute to decrease production costs and energy saving.

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3.16 Hard Coatings on Cutting Tools and Surface Finish

Comprehensive Materials Finishing ◽

10.1016/b978-0-12-803581-8.09178-5 ◽

2017 ◽

pp. 230-242 ◽

Cited By ~ 11

Author(s):

H. Caliskan ◽

P. Panjan ◽

C. Kurbanoglu

Keyword(s):

Surface Finish ◽

Cutting Tools ◽

Hard Coatings

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COMPARISON OF EXPERIMENTALLY MEASURED AND SIMULATED WORKPIECE AND GRINDING WHEEL TOPOGRAPHY USING A NEW DRESSING MODEL

Transactions of the Canadian Society for Mechanical Engineering ◽

10.1139/tcsme-2016-0001 ◽

2016 ◽

Vol 40 (1) ◽

pp. 1-17 ◽

Cited By ~ 1

Author(s):

Abdalslam Darafon ◽

Andrew Warkentin ◽

Robert Bauer

Keyword(s):

Surface Finish ◽

Metal Removal ◽

Ground Surface ◽

Cutting Edge ◽

Edge Density ◽

Grinding Wheel ◽

Workpiece Surface ◽

Wheel Topography ◽

Grinding Wheel Topography ◽

Grinding Conditions

This paper presents a new empirical model of the dressing process in grinding which is then incorporated into a 3D metal removal computer simulator to numerically predict the ground surface of a workpiece as well as the dressed surface of the grinding wheel. The proposed model superimposes a ductile cutting dressing model with a grain fracture model to numerically generate the resulting grinding wheel topography and workpiece surface. Grinding experiments were carried out using “fine”, “medium” and “coarse” dressing conditions to validate both the predicted wheel topography as well as the workpiece surface finish. For the grinding conditions used in this research, it was observed that the proposed dressing model is able to accurately predict the resulting workpiece surface finish for all dressing conditions tested. Furthermore, similar trends were observed between the predicted and experimentally-measured grinding wheel topographies when plotting the cutting edge density, average cutting edge width and average cutting edge spacing as a function of depth for all dressing conditions tested.

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Reinforcement and Cutting Tools Interaction during MMC Machining - A Review

Nano Hybrids and Composites ◽

10.4028/www.scientific.net/nhc.22.47 ◽

2018 ◽

Vol 22 ◽

pp. 47-54 ◽

Cited By ~ 1

Author(s):

Mukesh Chaudhari ◽

M. Senthil Kumar

Keyword(s):

Tool Wear ◽

Metal Matrix Composites ◽

Process Parameters ◽

Surface Finish ◽

Metal Matrix ◽

Cutting Tools ◽

Tool Geometry ◽

Matrix Composites ◽

Good Surface ◽

Aerospace Medical

Aluminum based metal matrix composites (AMMC) have found its applications in the automobile, aerospace, medical, and metal industries due to their superior mechanical properties. Fabricated Aluminum based metal matrix composites require machining to improve the surface finish and dimensional tolerance. Machining should be accomplished by good surface finish by consuming lowest energy and less tool wear. This paper reviews the machining of Aluminum based metal matrix composites to investigate the effect of process parameters such as tool geometry, tool wear, surface roughness, chip formation and also process parameters.

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Diamond Coatings for Machining: Coating Thickness Effects

ASME 2009 International Manufacturing Science and Engineering Conference, Volume 1 ◽

10.1115/msec2009-84358 ◽

2009 ◽

Author(s):

Feng Qin ◽

Y. Kevin Chou ◽

Dustin Nolen ◽

Raymond G. Thompson

Keyword(s):

Residual Stresses ◽

Coating Thickness ◽

Cutting Forces ◽

Failure Modes ◽

Cutting Tools ◽

Cutting Edge ◽

The Other ◽

Diamond Coatings ◽

Coated Tools ◽

Other Hand

Chemical vapor deposition (CVD)-grown diamond films have found applications as a hard coating for cutting tools. Even though the use of conventional diamond coatings seems to be accepted in the cutting tool industry, selections of proper coating thickness for different machining operations have not been often studied. Coating thickness affects the characteristics of diamond coated cutting tools in different perspectives that may mutually impact the tool performance in machining in a complex way. In this study, coating thickness effects on the deposition residual stresses, particularly around a cutting edge, and on coating failure modes were numerically investigated. On the other hand, coating thickness effects on tool surface smoothness and cutting edge radii were experimentally investigated. In addition, machining Al matrix composites using diamond coated tools with varied coating thicknesses was conducted to evaluate the effects on cutting forces, part surface finish and tool wear. The results are summarized as follows. (1) Increasing coating thickness will increase the residual stresses at the coating-substrate interface. (2) On the other hand, increasing coating thickness will generally increase the resistance of coating cracking and delamination. (3) Thicker coatings will result in larger edge radii; however, the extent of the effect on cutting forces also depends upon the machining condition. (4) For the thickness range tested, the life of diamond coated tools increases with the coating thickness because of delay of delaminations.

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Reamers cutting edge preparation for improvement the GGG 40 machining

MATEC Web of Conferences ◽

10.1051/matecconf/201817801014 ◽

2018 ◽

Vol 178 ◽

pp. 01014

Author(s):

Ioan-Doru Voina ◽

Stefan Sattel ◽

Glad Contiu ◽

Adrian Faur ◽

Bogdan Luca

Keyword(s):

Wear Resistance ◽

Coating Layer ◽

Cutting Tools ◽

Cutting Edge ◽

Abrasive Jet Machining ◽

Edge Wear ◽

Solid Carbide ◽

Cutting Edge Preparation ◽

Machining Strategies ◽

Edge Preparation

The improvement of the microgeometry became a subject of a great interest in cutting tools optimization. This paper approaches the process of cutting edge preparation of solid carbide reamers. It has been analyzed the evolution of cutting edge wear resistance in the material GGG 40 using the scanning electron microscope (SEM). The work also compared the rounded cutting edge reamers realized using wet abrasive jet machining with standard unprepared cutting edge. To obtain different microgeometries were experienced a number of machining strategies, which resulted in four combinations of roundness and forms for the cutting edge. In order to validate the results, the author studied the wear resistance during the reaming tests, the influence of prepared surface of the cutting edge on metallic coating layer adhesion. The final purpose was to determinate the optimal strategy of cutting edge preparation considering the evolution of wear during the reaming process.

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