Abstract
Tool geometric parameters have a huge impact on tool wear. Up to now, there are only a few researches on tool geometric parameters and optimization, and the single objective function of parameter optimization used by researchers during high‐speed machining (HSM) mainly is the minimum cutting force. However, the elevated cutting temperature also greatly affects tool wear due to the numerous cutting heat generation. Thus, to reduce tool wear, it is the most fundamental approach to taking into account the comprehensive control of the cutting force and cutting temperature because they are the two most important physical quantities in metal cutting processes. This work proposes a new optimization idea of the cutting‐tool’s multi geometric parameters (three main parameters: rake angle, clearance angle, and cutting edge radius) with two objective functions (the cutting force and the temperature). Based on the response surface method (RSM), we have established the modified functional relation models of the influence of tool geometric parameters on the cutting force and temperature according to the finite element simulation results in high‐speed cutting of Ti6Al4V. Then the models are solved by using a genetic algorithm, and the optimal tool geometric parameters values that can concurrently control the two objectives in their minimum values are obtained. The advantages lie in the strategy of the separate models of the cutting force and cutting temperature owing to their different dimensions and the solution of the models through giving the cutting force and cutting temperature different weight coefficients. The optimal results are verified by experiments, which shows that the optimal tool geometric parameters are very effective and vital for ensuring both the cutting force and the cutting temperature not too high. This work is of great significance to the cutting tool design theory and its manufacturing for reducing tool wear.
Highlights
In a metal cutting process, a cutting tool is the most direct factor affecting the cutting process
During high-speed machining of Ti6Al4V, serrated chips are always obtained under various different cutting conditions, and all finite element simulations show that when two of tool geometric parameters keep unchanged, the variation trends of cutting forces and cutting temperatures are almost the same with the change of the remaining one
(1) we study the influence laws of single parameter on single objective using finite element simulations first; (2) we combine them to establish the modified functional relations models between three tool geometric parameters and two objectives based on the response surface method (RSM); (3) the models are
Summary
In a metal cutting process, a cutting tool is the most direct factor affecting the cutting process. The cutting force, cutting heat, tool life, and surface quality of the workpiece are closely related to the tool geometric parameters. On the premise of some fixed factors such as machine tools, cutting tool material, workpiece material, and cutting parameters, tool geometric parameters will influence the cutting performance of the cutting tool, prolong tool life, and greatly improve productivity. Lo [3] conducted cutting simulations under different tool rake angles to explore the effect of the tool rake angle on cutting force in machining of oxygen-free high conductivity copper (OFHC). The findings indicate that an increase in the tool rake angle leads to a decrease in the cutting force and the cutting-force reduction is most evident as the rake angle increases from 10° to 15°. Wyen and Wegener [4] investigated the influence of the cutting edge radius on cutting forces in machining titanium, and the results show that the cutting force components increase with the increase of rounded cutting edges
Sign-in/Register to view highlights & summary 
Published Version (
Free)
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a call