Abstract
Tungsten carbide is the most preferred cutting tool material because of its superior properties. But tools made from the material require appropriate coating, rake angles, and tool geometry to optimize the cutting forces, tool life, and surface quality. However, microgeometry has a higher influence on the performance of the tool and stress formed on the workpiece. This study focuses on the effect of form factor (also called as “K-factor” or “symmetricity of hone radius”) on forces, surface roughness, and spindle power in face milling of AISI 4140 steel. The benefits of reverse-waterfall honed edge (also called as “trumpet hone”) over the symmetrically honed edge was studied by analysing the performance of milling inserts with K=1, K=1.3, and K=1.6. Apart from studying the effect of form factor on performance, the novelty of the investigation is to study the continuity of the form factor (duration) as machining progresses.
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