Abstract
The amount of flank wear is often used as the criterion for tool life assessment because it influences work material surface roughness and accuracy. In this study, the influence of cutting tool geometry (angles) on morphology of flank wear land during turning of low carbon steel is investigated by using image processing techniques and Response Surface Methodology (RSM). The analysis was based on a second order model in which the flank wear (area and shape factors) is expressed as a function of three cutting tool geometry parameters (relief angle, rake angle and cutting edge angle) and the effect of tool geometry parameters and their interactive effect on flank wear land morphology have been investigated. It is found that the area and shape factors of flank wear land are highly affected by the cutting tool geometry parameters considered in the present study.
Highlights
Tool wear has been identified as the most undesirable characteristic of machining operations
The mathematical models between morphology of wear land and the tool geometry (relief angle (α), rake angle (γ) and cutting edge angle (χ) of cutting tool) obtained from the response surface methodology analysis are given as follow: The model obtained for area of flank wear land: The model obtained for elongation factor: YEF = 4.599 + 2.3037 α − 0.090673 γ + 0.17201 χ −
The analysis of the effects of the cutting tool geometry variables (relief angle (α), rake angle (γ) and cutting edge angle (χ)) on the flank wear area were performed based on Eq (1)
Summary
Tool wear has been identified as the most undesirable characteristic of machining operations. Shahabi et al (2009a, b) developed a vision based method that can be used to detect notch wear from a single image of cutting tool in the micrometer range. In their other research (2009) the flank wear land width in zone C (VBC) was measured using 2-D images of nose profile and the workpiece roughness profile. Image processing techniques and response surface methodology is used to investigate the relationship between tool edge geometry parameters (e.g., relief angle, rake angle and cutting edge angle) on the morphology characteristics of flank wear land (e.g., the area and shape factors). The results show that area and shape factors of flank wear land is highly affected by the geometry of cutting tool and some of them has linear relationship
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