The effect of tool edge preparation on tool life and workpiece surface integrity

2004 ◽  
Vol 218 (9) ◽  
pp. 1113-1123 ◽  
Author(s):  
J I Hughes ◽  
A R C Sharman ◽  
K Ridgway
Keyword(s):  
Tool Life ◽  
Surface Integrity ◽  
Workpiece Surface ◽  
Tool Edge ◽  
Edge Preparation

The Effect of Tool Edge Geometry on Tool Performance and Surface Integrity in Turning Ti-6Al-4V Alloys

2011 ◽  
Vol 264-265 ◽  
pp. 1211-1221 ◽  
Author(s):  
Yanuar Burhanuddin ◽  
Che Hassan Che Haron ◽  
Jaharah A. Ghani
Keyword(s):  
Tool Life ◽  
Surface Integrity ◽  
Feed Rate ◽  
Cutting Speed ◽  
Optical Microscope ◽  
Edge Geometry ◽  
Tool Performance ◽  
Tool Edge ◽  
Structural Deformations ◽  
Notch Wear

This paper focuses on the influence of cutting tool edge geometry, cutting speed and feed rate on the tool performance and workpiece’s surface integrity in dry turning of Ti-6Al-4V alloy using PCBN inserts. The parameters evaluated are tool life, wear rate, wear mechanisms, surface roughness and subsurface microstructure alterations. The rate of wear growth of the insert was assessed by progressive flank wear using optical microscope by taking photographs after certain length of cut. The wear mechanism at the end of tool life was investigated in detail using scanning electron microscope (SEM) and EDAX analysis. The results show, by increasing the cutting speed and feed rate resulted in tool life reduction. Cutting with honed edge insert at cutting speed of 180 m/min has shown very little wear, even after 20 min of cutting. The honed insert proved less sensitive to increases in feed rate than the chamfered insert. In general the honed insert showed a significant improvement in tool life. All inserts failed due to attrition wear and adhesion. No flank notch wear was observed, but some crater wear occurred at the chamfer land. Microstructure alteration was not found when machining using the different edge geometry. In these trials, the subsurface micro structural deformations in the direction of cutting were deformed grain boundaries and elongation of grains. Chip smearing and debris on the surface was also found.

Influence of Edge Preparation Parameters on the Cutting Edge in Drag Finishing

2016 ◽  
Vol 693 ◽  
pp. 1067-1073 ◽  
Author(s):  
Xue Feng Zhao ◽  
Lin He ◽  
Sen Yuan ◽  
Wei Juan Zheng
Keyword(s):  
Cutting Edge ◽  
Workpiece Surface ◽  
Orthogonal Experiments ◽  
Spindle Rotation ◽  
Tool Edge ◽  
Milling Tool ◽  
The Stability ◽  
Drag Finishing ◽  
Edge Preparation

Tool edge preparation can eliminate defects and realize hone cutting edge, which can improve the quality of the workpiece surface, elevate the stability of cutting process and the tool life. In order to better investigate the edge preparation mechanism, the influence law of the edge preparation process parameters on the cutting edge is analyzed. The paper presents the single factor experiments and orthogonal experiments with the cemented carbide milling tool spindle rotation rate, edge preparation time, abrasive size and abrasive ratio in drag finishing. The edge preparation mechanism is revealed in the paper, which provides basis for the structure optimization of cutting edge contour.

Study on the Influence of Different Tool Edge Radius on Milling Ti6Al4V

2010 ◽  
Author(s):  
Yueping Liu ◽  
Jianfeng Li ◽  
Jie Sun ◽  
Feng Jiang
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Tool Life ◽  
Chip Morphology ◽  
Element Model ◽  
Fem Model ◽  
Edge Radius ◽  
Cutting Heat ◽  
Tool Edge ◽  
Edge Preparation

Short tool life is one of the bottleneck problems in Ti6Al4V machining. Edge preparation plays an important role on tool life. To investigate the influence of edge preparation on cutting force, cutting heat and chip morphology et al, Finite element model (FEM) is established. The software adopted in this study is ThirdWaveSystems AdvantEdge. Experiment is designed to verify the validation of the FEM model. Based on the validated FEM, optimized edge radius is obtained.

High-feed turning of AISI D2 tool steel using multi-radii tool inserts: Tool life, material removed, and workpiece surface integrity evaluation

2016 ◽  
Vol 32 (6) ◽  
pp. 670-677 ◽  
Author(s):  
Sarmad Ali Khan ◽  
Muhammad Aftab Ahmad ◽  
Muhammad Qaiser Saleem ◽  
Zakria Ghulam ◽  
Muhammad Asif Mahmood Qureshi
Keyword(s):  
Tool Life ◽  
Tool Steel ◽  
Surface Integrity ◽  
Workpiece Surface ◽  
Aisi D2 ◽  
High Feed ◽  
Aisi D2 Tool Steel

Design for Manufacturing of Variable Microgeometry Cutting Tools

2017 ◽  
Vol 140 (1) ◽  
Author(s):  
N. Z. Yussefian ◽  
A. Hosseini ◽  
K. Hosseinkhani ◽  
H. A. Kishawy
Keyword(s):  
Tool Life ◽  
Wedge Angle ◽  
Cutting Tools ◽  
Cutting Edge ◽  
Machining Process ◽  
Valuable Insight ◽  
Machining Parameters ◽  
Workpiece Surface ◽  
Coated Carbide ◽  
Edge Preparation

Cutting edge microgeometry has gained special attention of late in the machining research community. Machine tool vibration, tool life, and workpiece surface integrity are all influenced by cutting edge size/shape. To optimize the machining process, variable microgeometry (VMG) cutting tools, in which the edge microgeometry varies along the edgeline with respect to specific variables (such as machining parameters or expected tool wear), are manufactured. Despite the advantages of VMG tools, a major hindrance in their development is the manufacturing complexity that demands high precision multi-axis edge preparation processes following extensive machine setup, fixturing, and programming. This paper details the proof of concept of a design criterion, which leads to the manufacturing of VMG cutting tools by only traditional edge preparation processes. The present method relies on the existing relationship between the edge radius subsequent to the edge preparation process and the tool wedge angle. The validity of the proposed method is first examined by a numerical simulation of the edge preparation. Carbide cutting tool inserts are then designed based on the proposed idea. Robust VMG generation subsequent to edge preparation by microblasting is demonstrated through microgeometric measurements. VMG chemical vapor deposition-coated carbide tools manufactured by the proposed approach are evaluated for turning hardened steel, and optimal designs are identified with respect to tool life and workpiece surface roughness. To address the design consideration, finite element (FE) modeling provides valuable insight into the machining process. FE modeled stress and temperature distribution clarify the experimental observations and reveal the design constraints.

scholarly journals Influence of tool edge form factor and cutting parameters on milling performance

2021 ◽  
Vol 13 (4) ◽  
pp. 168781402110090
Author(s):  
Xuefeng Zhao ◽  
Hao Qin ◽  
Zhiguo Feng
Keyword(s):  
Form Factor ◽  
Simulation Model ◽  
Cutting Force ◽  
Surface Quality ◽  
High Speed ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Tool Edge ◽  
Drag Finishing ◽  
Edge Preparation

Tool edge preparation can improve the tool life, as well as cutting performance and machined surface quality, meeting the requirements of high-speed and high-efficiency cutting. In general, prepared tool edges could be divided into symmetric or asymmetric edges. In the present study, the cemented carbide tools were initially edge prepared through drag finishing. The simulation model of the carbide cemented tool milling steel was established through Deform software. Effects of edge form factor, spindle speed, feed per tooth, axial, and radial cutting depth on the cutting force, the tool wear, the cutting temperature, and the surface quality were investigated through the orthogonal cutting simulation. The simulated cutting force results were compared to the results obtained from the orthogonal milling experiment through the dynamometer Kistler, which verified the simulation model correctness. The obtained results provided a basis for edge preparation effect along with high-speed and high effective cutting machining comprehension.

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