Tool nose radius effects in turning process

Abstract

The main goal of this article is to study the effects of tool nose radius on some performances in turning process. An analytical approach is developed and adapted for cutting with round inserts or when only the round edge was engaged in the metal. The uncut chip area is evaluated as function to tool nose radius and discretized into some elements which are defined by their average uncut chip thickness and elementary edge direction angle. Cutting edge radius is considered and minimum uncut chip thickness is evaluated for each element. Hence, two mechanisms are studied in relation to the minimum uncut chip thickness: cutting and plowing. Effects of tool nose and cutting edge radii on cutting force components, tool/chip interface temperature, specific cutting energy, tool/chip contact length and chip thickness are investigated. Good agreement was found between experiments and predictive cutting forces when turning stainless steel.