Development of Machining Device with Real-Time Visualization of Boundary Surface on Tool Rake Face and Cutting Chip

Abstract

Analysis of cutting phenomena has been conducted for a long time and many researchers have elucidated the phenomena that may occur at the cutting-edge during machining; for example, built-up edges and welding phenomena on cutting edge. However, the existing research has focused on observing the tool and chips after machining, when the tool and work material have been cooled, and are under atmospheric pressure. Therefore, we consider that it is different from the phenomenon that occurs during cutting. Because the cutting edge of a tool is in a high-temperature and high-pressure environment during machining and is released from such an environment after machining, the cutting edge must be visualized to discuss the actual cutting phenomena. There have been research reports in the past that have visualized the backside of cutting chips; however, that experiment was far from actual cutting phenomena and was conducted at significantly low cutting speed. Thus, the visualization of the cutting phenomenon is physically extremely difficult at the cutting edge. Under such circumstances, this study developed a device that observed the behavior of the boundary surface between cutting chips and the rake face in real time from the backside of the rake face during machining. By using the developed device, we could visualize this phenomenon to acquire the data directly and visually, which can otherwise be grasped only indirectly. In this device, a camera was mounted on a tool holder, and a cutting tip made of a transparent material was used to observe rake face, cutting edge, and flank face which can be visualized during machining from the backside of the rake face within one field of view. This paper reports on the outline of the developed device, its method, and the results of experimental observation of the state of two-dimensional cutting using a lathe.