Simulation and Experimental Study on the Effect of Edge Radius on the Cutting Condition of Carbide Inserts

Abstract

Carbide tools are extensively used in the automotive, aerospace, and marine industries. However, an unsuitable tool-edge treatment can affect the cutting performance of carbide tools. In the tool-cutting process, the cutting edge radius is one of the major factors that affect the cutting force, temperature, and quality. In this study, a cutting simulation model of carbide inserts was used to analyze the effect of the cutting edge radius on the cutting performance. The cutting edge radii of the inserts were prepared using shear-thickening polishing methods, followed by cutting experiments. The accuracy of the cutting simulation model was verified through cutting experiments. The simulation results showed that under low-speed cutting conditions, the cutting force and temperature tended to increase with an increase in the cutting edge radius, and the cutting temperature was less affected by the cutting edge radius. The results of the cutting force and cutting temperature obtained from the experiment and simulation were consistent; therefore, the cutting simulation model was verified to be reliable. The results indicate that modeling cutting simulation is a promising research method for predicting the cutting performance of tools.