Abstract
The performance of cutting tools can be significantly enhanced by matching the cutting edge rounding to the process and material properties. However, the conventional cutting edge rounding design is characterized by a significant number of experimental machining studies, which involve considerable cost, time, and resources. In this study, a novel approach to cutting edge rounding design using FEM-based chip formation simulations is presented. Based on a parameterized simulation model, tool temperatures, stresses and relative velocities can be calculated as a function of tool microgeometry. It can be shown that the external tool loads can be simulated with high agreement. With the help of these loads and the use of wear models, the resulting tool wear and the optimum cutting edge rounding can be determined. The final experimental investigations show a qualitatively high agreement to the simulation, which will enable a reduced effort design of the cutting edge in the future.
Highlights
Cutting edge preparation is state of the art in the manufacture of cutting tools.Cutting of edge state of the art on in the of cuttingoftools.KnowlKnowledge thepreparation influence ofismicrogeometry the manufacture application behavior cutting tools edge of microgeometry on the of application behavior of cutting plays a playsofa the keyinfluence role in a complete understanding the process [1]
The normal stress is especially challenging for a comparison with the simulation due to the fact that the experimentally determined normal stresses are based on methods which do not represent the cutting process sufficiently accurately, for example by using split tools or stress–optical materials
In order to consider all the materials, the normal stresses are shown for a cutting edge rounding of Sα = Sγ = 30 μm
Summary
Cutting edge preparation is state of the art in the manufacture of cutting tools.Cutting of edge state of the art on in the of cuttingoftools.KnowlKnowledge thepreparation influence ofismicrogeometry the manufacture application behavior cutting tools edge of microgeometry on the of application behavior of cutting plays a playsofa the keyinfluence role in a complete understanding the process [1]. Cutting edge preparation is state of the art in the manufacture of cutting tools. Cutting of edge state of the art on in the of cuttingoftools. KnowlKnowledge thepreparation influence ofismicrogeometry the manufacture application behavior cutting tools edge of microgeometry on the of application behavior of cutting plays a playsofa the keyinfluence role in a complete understanding the process [1]. Cutting edgetools microgeomkey in a complete understanding thewith process [1]. Cutting edge microgeometry is etryrole is commonly described as an idealofarc a radius of rβ. Further investicommonly described as an ideal arc with a radius of r
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