Abstract
Tool-edge wear (i.e., the wear of a tool cutting edge before it is fully worn away) is among significant concerns in high-speed machining because it can result in early tool failure and deteriorated quality of machined parts. Based on extensive experimental results, this paper shows how tool-edge wear is correlated with the cutting forces and vibrations in high-speed turning of Inconel 718. The following research findings are made from the present study: 1) The development of tool-edge wear depends on the initial tool-edge geometry and the cutting conditions employed. 2) The amount of tool-edge wear varies at different measurement points along the tool cutting edge, and increases as the feed rate increases. 3) The effect of tool-edge wear on the cutting forces depends on the initial tool-edge geometry and the cutting conditions employed. 4) The traditional time-domain analysis based on the vibration amplitude is not helpful in explaining and showing the dynamic development of tool-edge wear, and wavelet packet transform helps in identifying the changes in the vibration signals in different frequency bands.
Highlights
Tool wear in high-speed machining (HSM) has long been a significant concern because it shortens tool life, increases cutting forces, temperatures, and vibrations, and deteriorates the quality of machined parts or components [1] to [3]
4) The traditional time-domain analysis based on the vibration amplitude is not helpful in explaining and showing the dynamic development of tool-edge wear, and wavelet packet transform helps in identifying the changes in the vibration signals in different frequency bands
As tool-edge geometry plays a significant role in machining at small feed rates [28] and [29], tool-edge wear significantly contributes to early tool failure and deteriorated quality of machined components and parts
Summary
Tool wear in high-speed machining (HSM) has long been a significant concern because it shortens tool life, increases cutting forces, temperatures, and vibrations, and deteriorates the quality of machined parts or components [1] to [3]. Tool wear can be classified into different types according to its mechanisms (i.e., the reasons that cause tool wear) or its forms (i.e., the locations on a cutting tool) [4] and [5]. There are crater wear, flank wear, notch wear, chip-groove wear, and so on. Extensive literature review shows that the forms of tool wear that have been widely studied are crater wear [6] and [7] and flank wear [8] and [9]. Tool-edge wear is defined as “the wear of a tool cutting edge before it is fully worn away [11].”. Tool-edge wear is defined as “the wear of a tool cutting edge before it is fully worn away [11].” Fig. 1 shows the location of tool-edge wear on a cutting tool, including a 3D view and a 2D cross-sectional view of the tool cutting edge
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