Abstract
The cutting-edge radius of the tool has significant effects on the machining process, as it influences the cutting forces, stresses, and temperature at the tool–chip interface. These parameters ultimately affect the tool life and surface integrity of the finished workpiece. The presence of cutting-edge radius in the tools protects them from easily chipping off during the cutting process. A finite element based ABAQUS™ model is used to evaluate the effect of cutting-edge radius for 20, 40, and 60 μm on the cutting forces for orthogonal cutting of Ti6Al4V alloy at different cutting parameters. It was observed that the cutting-edge radius influences both the cutting and thrust forces. An increase of 4–8% and 12–14% in the cutting force and thrust force was observed when the cutting-edge radius changes from 20 to 60 μm. The temperature in the tool was increased with increasing cutting-edge radius.
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