The preparation of cutting edges using a marking laser

Abstract

During the machining process, high mechanical and thermal loads occur at the cutting edge. Such loads can cause tool failure. Specifically non-uniform and sharp cutting edges that have a low cutting edge stability lead to such failures. In order to enhance the tool performance, the cutting edges are prepared by manufacturing both a pre-defined cutting edge geometry, and an appropriate cutting edge roughness. This paper describes the use of a low-cost marking laser for the preparation of cutting edges as an alternative to conventional preparation techniques, such as brushing or blasting. Cutting edge radii of 9–47 μm can be prepared with a machining accuracy of 1.5 μm. The maximum preparation time for an individual cutting edge is approximately 10 s. Uncoated indexable inserts manufactured in this way were tested in a face milling operation. The results of these investigations (using prepared cutting edges) show both an increase in tool life and an improved surface roughness of the machined workpieces compared to those using non-prepared cutting edges.