Innovative method for cutting edge preparation with flexible diamond tools

Abstract

The micro geometry of the cutting edge is of central importance for the performance of cutting tools. It influences all essential parameters in the machining process: chip formation, thermal and mechanical load on the tool and the workpiece, tool wear and the resulting workpiece quality. The effect depends on the size and shape of the cutting edge rounding. Depending on the machining process, asymmetrical roundings often show the greatest potential. In addition to increasing tool life, the quality of the surfaces produced can be improved by a specifically designed asymmetrical rounding. For edge preparation, blasting, brushing and drag finishing are used in industrial applications. However, an economic production of asymmetrical cutting edge geometries on cutting tools with complicated cutting edge geometry, such as solid carbide tools with helical cutting edge, cannot be achieved with these methods. Therefore, a novel method for preparation of the cutting edge rounding using flexible bond diamond polishing tools is introduced. Hence, the conducted research in this study analyzes the basic mechanisms and influencing factors using the new preparation method. For this purpose, polishing tests are carried out on carbide indexable inserts. The results show that the polishing tools can be used to create both asymmetrical and symmetrical roundings in an industrially relevant dimension.