Determination of the Real Cutting Edge Wear Contact Area on the Tool-Workpiece Interface in the Light of Cutting Forces Variations

Abstract

The determination of actual stresses over the tool-workpiece interface has long been a matter of debate among researchers. Evaluation of the nature and the geometry of the wear contact area were always associated with many, sometime impractical, assumptions. The indeterministic fashion of edge wear and deformation requires a more realistic way to predict the actual wear contact area. In the current study, many wear area patterns are proposed considering the different wear modes of the cutting edge. The selection of the most correlated pattern to a specific edge deformation is justified using the relevant variations in the radial and the axial force components. For a regular wear over the entire cutting edge, a wear pattern that considers nose and/or flank is justified. When the cutting edge plastically fails, a pattern that considers only nose wear is preferred. As the cutting edge is subjected to many types of irregular disturbances of edge fracture and chipping, a wear pattern considering both flank and nose wear is selected.