Edge Radius Research Articles

Finite Element Simulation of Ti-6Al-4V Alloy Machining with a Grain-Size-Dependent Constitutive Model Considering the Ploughing Effect Under MQL and Cryogenic Conditions

The finite element modeling method has been widely applied in the modeling of the cutting process to characterize the instantaneous and microscale deformation mechanism that was difficult to obtain using physical experiments. The lubrication and cooling conditions, such as minimum quantity lubrication and cryogenic liquid nitrogen, affect the thermo-mechanical behaviors and machined surface integrity in the cutting process. In this work, a grain-size-dependent constitutive model was used to model orthogonal cutting for Ti-6Al-4V alloy with MQL and LN2 conditions. The cutting forces and chip morphologies that were measured in the cutting experiments of Ti-6Al-4V alloy were used to validate the simulated forces. The relative errors between the measured and simulated principal forces were less than 8%, while the relative errors of thrust forces were less than 19%. The predicted chip morphologies and surface grain refinement agreed well with the experimental results under the conditions with different uncut chip thicknesses and edge radii. Additionally, the relationship between the plastic displacement and grain refinement, as well as the microhardness and residual stresses under MQL and cryogenic conditions, were discussed. This work provides an effective modeling method for the orthogonal cutting of Ti-6Al-4V alloy to understand the mechanism of the plastic deformation and machined surface integrity under the MQL and LN2 conditions.

Investigation on the influence of mesoscale geometric features on the surface white layer characteristics in titanium alloy milling using ball end mills

A white layer will be generated on the machined surface when milling titanium alloy. Its existence will make the surface of the workpiece more brittle, and it is easy to produce cracks during the machining process, which greatly harms machining. Aiming at this problem, this paper takes the ball-end milling cutter with mesoscopic geometric characteristics as the research object, establishes the theoretical model of the white layer thickness of the workpiece under the micro-texture and cutting edge factors, analyzes the single factor of micro-texture parameters and cutting edge parameters, and the interaction between them and cutting parameters on the milling force-thermal characteristics and the white layer of the workpiece. The influence law reveals its mechanism from the macro and micro perspectives. It uses the white layer thickness as the evaluation index to optimize the mesoscopic geometric characteristic parameters by using the simulated annealing algorithm. The results demonstrate that the mesoscopic geometric feature of the ball-end milling cutter effectively reduces the thickness of the white layer, achieving a 38% reduction compared to that observed with a non-textured milling cutter. The thickness of the white layer exhibits a positive correlation with the distance L from the blade and a negative correlation with the edge radius R. The interaction between the cutting edge radius R and the cutting depth a p influences the milling force and heat, alters the micro-texture of the workpiece surface, induces the α + β phase transformation, and affects the white layer thickness. Based on the predictive model for white layer thickness, the optimization results for comprehensive milling performance are as follows: R is 59.39 μm, L is 110.01 μm, D is 58.68 μm, L1 is 130.59 μm, a p is 0.30 mm, V is 147.39 mm/min, f is 0.08 mm/z.

Influences of size effect and workpiece temperature during cryogenic micro milling of soft viscoelastic polymer: an experimental assessment

Application of tool-based micromachining in soft polymer has been limited due to high adhesion and low elastic modulus of this material at room temperature. This study aims to evaluate the machinability of a typical viscoelastic soft polymer and understand the effect of material and process parameters on machining performances. In this study, a micro-milling process using cryogenic-assisted cooling is proposed and the importance of temperature control toward glass transition zone was particularly addressed. To identify insight of machinability in micro domain, this article also determines minimum uncut chip thickness (MUCT) and size effects by considering the variations of cutting force and surface integrity with the ratio of h/re (uncut chip thickness (h) to cutting edge radius (re)). The experimental results reveal that consideration of size effect during micromilling of soft viscoelastic polymer helps in reduction of machined surface roughness (Sa) value. Based on the cutting force pattern, it is evaluated that higher machining stability can be achieved during cryogenic machining by reduction of specific cutting force value. Moreover, temperature range around glass transition zone yields more promising experimental outcomes, outperforming other cooling zones.

Impacting factors and operation thresholds of electron transpiration cooling-based thermal protection system

Electron transpiration cooling (ETC) is a spontaneous endothermic process that occurs during thermionic emission, which shows great potential in ultra-high-temperature thermal protection systems (TPS). Herein, we systematically analyze the main influencing factors on the cooling effect of ETC, such as incoming flow velocity, geometry, and material work function. A two-dimensional finite element model, based on Navier-Stokes equations coupled with the 11-species air reaction model and two-temperature model, is developed to solve the thermal interaction between ETC and the non-equilibrium flow field. Three operational thresholds for ETC are identified. Lower work functions enhance electron emission, thereby reducing wall temperature. With a 2.0 eV work function, ETC significantly outperforms blackbody radiation at 1360 K, and its cooling efficiency increases with temperature. For flow velocities above Mach 9.0, ETC is effective at the leading edge with a 2.4 eV work function and a 5 mm radius. However, it loses effectiveness with a 300 mm leading edge radius, even at Mach 16.0. Notably, at Mach 19.6, with a 2.0 eV work function and a 5 mm radius, ETC reduces surface temperature by up to 48.1 %. These findings highlight the considerable potential of ETC for applications in ultra-high-temperature TPS. These findings highlight the considerable potential of ETC for applications in ultra-high-temperature TPS.

Inverse Identification of Constitutive Model for GH4198 Based on Genetic-Particle Swarm Algorithm.

A precise Johnson-Cook (J-C) constitutive model is the foundation for precise calculation of finite-element simulation. In order to obtain the J-C constitutive model accurately for a new cast and forged alloy GH4198, an inverse identification of J-C constitutive model was proposed based on a genetic-particle swarm algorithm. Firstly, a quasi-static tensile test at different strain rates was conducted to determine the initial yield strength A, strain hardening coefficient B, and work hardening exponent n for the material's J-C model. Secondly, a new method for orthogonal cutting model was constructed based on the unequal division shear theory and considering the influence of tool edge radius. In order to obtain the strain-rate strengthening coefficient C and thermal softening coefficient m, an orthogonal cutting experiment was conducted. Finally, in order to validate the precision of the constitutive model, an orthogonal cutting thermo-mechanical coupling simulation model was established. Meanwhile, the sensitivity of J-C constitutive model parameters on simulation results was analyzed. The results indicate that the parameter m significantly affects chip morphology, and that the parameter C has a notable impact on the cutting force. This study addressed the issue of missing constitutive parameters for GH4198 and provided a theoretical reference for the optimization and identification of constitutive models for other aerospace materials.

Eco-friendly, lightweight, and high-strength sandwich corrugated particleboard from tea oil camellia (Camellia oleifera Abel.) shells

This study investigates the potential of developing corrugated panels from tea oil camellia shell (TOCS), an abundant agricultural waste in the southern provinces of China, with an annual production of approximately 4 million tons, using experimental and computational methods. Hence, various corrugated geometries were designed using AutoCAD software, and finite element analysis (FEA) was conducted using Ansys Mechanical software to optimize the panel geometry based on TOCS engineering data. Bending performance simulations revealed that a trapezoidal geometry with a 3 mm edge radius exhibited superior bending performance. Therefore, this geometry was selected to fabricate corrugated panels of different densities to assess the impact of density variation. Mechanical characterization included evaluation of bending stiffness, maximum moment, total deflection, compression strength, ultimate strength, dowel bearing strength, and face screw resistance of the panels was performed. Furthermore, specific energy absorption and failure mechanisms of mechanical tests were analyzed. The results indicate that TOCS-based sandwich panels, characterized by their lightweight and sustainable nature, not only meet, or exceed the criteria specified in APA PS 2–10 for use as structural materials but also mitigate the environmental hazards associated with landfill disposal or burning of agricultural waste.

Effects of Edge Radius and Coating Thickness on the Cutting Performance of AlCrN-Coated Tool

High-speed machining is a practical way to attain high productivity with lower costs. Under this condition, the tool geometry needs to be optimized to sustain high cutting forces and temperatures. The sharpness of the cutting edge and the coating thickness (CT) are two key parameters that affect the tool’s performance. While a sharp edge eases the cutting process, it causes a high stress concentration, which increases the wear rate and eventual edge fracture. In this study, we use a combination of finite element simulations and experimental testing to evaluate the effects of CT ( 1–3 μm), edge radius (rβ\\documentclass[12pt]{minimal} \\usepackage{amsmath} \\usepackage{wasysym} \\usepackage{amsfonts} \\usepackage{amssymb} \\usepackage{amsbsy} \\usepackage{mathrsfs} \\usepackage{upgreek} \\setlength{\\oddsidemargin}{-69pt} \\begin{document}$$r_{\\beta }$$\\end{document} , 6–15 μm), and coefficient of friction (μ=0-0.2\\documentclass[12pt]{minimal} \\usepackage{amsmath} \\usepackage{wasysym} \\usepackage{amsfonts} \\usepackage{amssymb} \\usepackage{amsbsy} \\usepackage{mathrsfs} \\usepackage{upgreek} \\setlength{\\oddsidemargin}{-69pt} \\begin{document}$$\\upmu = 0 - 0.2$$\\end{document}) on the stress distribution at the cutting edge. Our simulations showed that the larger the CT, the higher the stress magnitude inside the coating, but the lower the maximum stress depth percentile. Considering an industrial case of cutting steel workpieces using AlCrN-coated tungsten carbide tools under given cutting parameters, our simulations suggested an optimum CT of 3 μm. By manufacturing a series of milling tools with different CTs and edge radii, we validated the simulation results using a set of well-controlled milling experiments. Finally, the edge radius should be selected considering the size of rake/flank angle mainly to control stress distribution over the cutting edge.

Unraveling the complex interplay between elastic recovery, contact pressure, and friction on the flank face of the micro tools via plunging-type testing

A good understanding of the interplay between the cutting tool edge radius, elastic recovery, friction, and contact pressure is essential for better modeling of ploughing forces during micro-scale cutting. This study conducts plunging tests on an ultra-precision CNC with engineered tungsten carbide cutting tools on commercially pure titanium alloy. The cutting tool edge radius is prepared to be around 3.5–4 μm, which resembles those cutting tools used in micro scale machining. During plunging tests, the micro cutting tool is given a sinusoidal movement with an amplitude close to edge radius of the tool as the work material is rotated at a constant speed. The residual depth profiles of the webs corresponding to the commanded depths were investigated in detail to identify elastic recovery rate. The cutting and thrust force measurements during plunging experiments together with identified elastic recovery rate was employed in an analytical model of micro scale machining to obtain the variations of contact pressure and coefficient of friction as a function of commanded depth. Due to the scale of the experiments that were performed, the effects of surface topography of the cutting tool and possible alignment errors are also considered in the analytical model. A linear relationship between the contact pressure and elastic recovery has been identified during ploughing-dominated machining conditions for the work material and the cutting tool pair considered in this study. The proposed experimental technique is shown to be promising in terms of modeling ploughing forces during micro-scale cutting.

In plane mechanical properties of hexagonal V-chiral and Tri-chiral metamaterials

The reasonable design of man-made multifunctional metamaterials with advanced mechanical and physical properties that are not found in nature is both challenging and important. In this paper, novel chiral structures are designed by adding V- and Tri- chiral elements to the typical hexagonal honeycomb substrate, so as to realize the modulation of in plane mechanical properties. Finite element simulations show that the Poisson's ratio of the hexagonal V-chiral structure is negative when the strain is greater than 0.4, and that of the hexagonal Tri-chiral structure is always negative. Quasi-static compression tests show that the introduction of chiral properties results in a stronger load-bearing capacity, and the hexagonal Tri-chiral structure has a stronger energy absorption (EA) and specific energy absorption (SEA) capability. A parametric study is carried out by means of FEM, by adjusting the geometrical parameters of the proposed structures, the performance in terms of energy absorption and compressive stiffness can be improved. Subsequently, Bloch-Floquet theorem is employed for the dispersion relations of the chiral metamaterials and the results show that compared to conventional hexagonal honeycomb, chiral metamaterials are able to generate band gaps in a lower frequency range. Numerical simulation results show that the bandwidth of the proposed novel chiral metamaterials can be tuned through a reasonable selection of hexagonal edge length, wall thickness and radius. Experimental investigations are conducted to test the vibration transmission rate of Structure Ⅲ, and the results prove that the structure is capable of vibration suppression in the target frequency band range. Finally, by filling Structure Ⅲ with steel columns, the structure generates band gaps in the lower frequency range, hence the application of this chiral metamaterial is broadened.

The Effect of Rake Angle and Cutting Edge Radius on the Orthogonal Cutting Process of Ti6Al4V Alloy

This paper investigates the effect of rake angle, α, cutting edge radius, r, and feed rate, f, on the cutting force and cutting zone temperature during orthogonal dry cutting of Ti6Al4V. A numerical model representative of the 2D orthogonal cutting process is developed using ABAQUS/Explicit software. Johnson-Cook, (JC) constitutive material model is used to describe material plasticity. JC damage model and energy-based fracture criterion are used to describe damage initiation and evolution. Using Minitab-19 software, Taguchi L9 orthogonal array (3 × 3) is implemented to plan simulation trails. Assuming a constant cutting speed of 500 mm/min, three levels for each factor are considered α (-5°, 0°, 5°), <em>r</em> (0.02, 0.04, 0.06 mm) and <em>f</em> (0.1, 0.2, 0.3 mm). The cutting force and cutting zone temperature are analyzed using ANOVA. Based on a 90% Confidence Interval (90% CI), the results show that only feed rate significantly affects the cutting force. However, rake angle, cutting edge radius, and feed rate do not substantially affect cutting zone temperature.

Molecular dynamics simulation of the effect of tool parameters on nano-cutting of polycrystalline γ-TiAl alloys

As one of the most promising lightweight high-temperature structural materials in the future, the surface quality of γ-TiAl alloys has a great influence on the performance of the workpieces, and the tool parameters are an important factor affecting the machining results. In this study, molecular dynamics simulations of the nano-cutting process of polycrystalline γ-TiAl alloys with different tool parameters were carried out. The results show that increasing the tool rake angle and decreasing the tool edge radius within a certain range helps to reduce the average cutting force, cutting force fluctuation, cutting temperature, and stabilize the cutting process, while the change of the tool clearance angle has less influence on the cutting process. In contrast, negative rake angle cutting is more likely to produce grain rotation and grain boundary steps in the processed substrate and increase the processed surface roughness than positive rake angle cutting; increasing the tool rake angle within a certain range will weaken the elastic recovery effect of the substrate. During cutting at a positive rake angle, whether a portion of the substrate is prone to slip toward the surface of the substrate, thereby reducing the surface quality, depends on the relative state of grain orientation and force applied in the substrate.

Evaluation of tool wear during micro-milling of ultrasonically assisted abrasive peened Ti-6Al-4V

When a cutting tool shears through a workpiece, the interaction causes wear of the tool which is based on relative hardness, surface characteristics of the tool and the workpiece, cutting environment and thermal behaviour at the work/tool interface. In this study, wear of a micro-end milling tool is investigated while milling of as-received and peened work material (in this case, Ti-6Al-4V). The peening is performed with the help of an in-house developed ultrasonic cavitation process. The process excites the abrasives suspended in the cavitating medium, which impart on the work surface and induce compressive residual stress and uniform grain refinement. As the cutting process advances, a built-up is formed more rapidly in the as-received workpiece, leading to higher cutting forces and earlier chipping of the cutting edge. Under the peened conditions, it is found that the increase in tool edge radius and flank wear width reduce by 50 % and 54 % respectively compared to the as-received one. Additionally, peening-induced grain refinement leads to a 26 % decrease in surface roughness of the machined surface and inhibits burr formation by 60 %. A tool wear chipping model is employed to predict the tool diameter, cutting edge radius and flank wear width of the worn tool. Results show that the magnitude of flank wear, edge radius of worn tool and tool diameter deviate from experiments by 15.2 %, 14 % and 13 % respectively.

Mechanism and characterization of laser-assisted hybrid processing for chemical vapor deposited diamond micro milling cutters

The fabrication of superhard micro milling cutters with extreme sharpness is highly demanded to meet the strict requirements of micro structures in terms of machining accuracy, surface roughness and burr height. In this study, nanosecond laser induced graphitization assisted grinding was proposed by considering machining efficiency and machining quality simultaneously for chemical vapor deposited (CVD) diamond micro flat-end milling cutters. An optimal cut-section was obtained by adopting moderate laser cutting energy and avoiding unstable thermodynamic coupling effect. The following laser induced graphitization mechanism on the cut-section was studied by analysing the different graphitization behaviours. The extensive graphitization caused sintered and banded graphite while the weak graphitization could not eliminate the defects caused by laser cutting. The uniform and dense graphitization resulted from appropriate energy distribution contributed to the smooth transition layer which was the significant factor in subsequent grinding. Moreover, the subsequent grinding behaviours of different transition layers were investigated, the grooved defects on transition layer caused the unstable grinding and fracture removal model, leading to the cracked ground surface and blunt cutting edge. Nevertheless, the grinding model of smooth transition layer was scratching without transcrystalline cracks, resulting in the smooth ground surface and sharp cutting edge. Thus, the laser parameters were finally optimized based on the feedback. Furthermore, the even graphitization, undamaged transition layer, scratching, as well as less material stress resulted in the extreme sharpness. In this way, the CVD diamond micro flat-end milling cutter (CVDM) with a diameter of 200 μm, surface roughness Sa of 30 nm, aspect ratio of 3, and edge radius of around 0.12 μm was prepared, the extreme sharpness was indicated by comparing with the edge radius of 1–5 μm reported heretofore. Finally, the micro grooves with surface roughness Sa of 17.8 nm and tiny burrs were machined on Ti-6Al-4 V by the homemade CVDM, which thereby indicated the outstanding cutting performance of the CVDM in micro-milling.

Effects of Leading Edge Radius on Stall Characteristics of Rotor Airfoil

The effects of leading edge radius on the static and dynamic stall characteristics of rotor airfoils are investigated. Initially, a parametric airfoil (PARFOIL) method is employed to generate four morphed airfoils with different leading edge radii based on a NACA 0012 airfoil. Subsequently, the Reynolds-averaged Navier–Stokes (RANS) method is employed to simulate the aerodynamic characteristics of static airfoils, while the improved delayed detached-eddy simulation (IDDES) method is employed for pitching airfoils. The effectiveness and accuracy of the computational fluid dynamics (CFD) methods are demonstrated through favorable agreement between the numerical and experimental results. Finally, both the static and dynamic aerodynamic characteristics are simulated and analyzed for the airfoils with varying leading edge radii. Comparative analyses indicate that at low Mach numbers, the high adverse pressure gradient near the leading edge is the primary cause of leading edge separation and stall. A larger leading edge radius helps to reduce the suction pressure peak and adverse pressure gradients, thus delaying the leading edge separation and stall of airfoil. At high Mach numbers, the leading edge separation and stall are mainly induced by the shock wave. Variations in leading edge radius have minimal impacts on the high adverse pressure gradient induced by the shock wave, thus making the stall characteristics of airfoils almost unaffected at high Mach numbers.

Influence of tool flank wear considering tool edge radius on instantaneous uncut chip thickness and cutting force in micro-end milling

Influence of tool flank wear considering tool edge radius on instantaneous uncut chip thickness and cutting force in micro-end milling

Influence of trailing edge radius of intake struts on excitation force and vibration of rotor blades

Adjusting the trailing edge radius of the intake struts may be advantageous in suppressing the vibration of compressor rotor blades. To explore the impact of the intake struts trailing edge radius on the excitation force and vibration, this study focuses on a compressor with intake struts, and fluid and vibration calculations were conducted. The study revealed that decreasing the trailing edge radius led to a reduction in separation near the strut’s trailing edge, resulting in a narrower wake and weakened mixing near the trailing edge. This caused the total pressure loss region induced by the wake to become more elongated in the low-frequency component, leading to a nonlinear decrease in total pressure amplitude with the reduction of the trailing edge radius. As the trailing edge radius decreased, the excitation force and vibration amplitude of the first-stage compressor rotor blades decreased, while the excitation force distribution showed little variation. The research findings provide insights for the design of intake struts.

The Fan Design Optimization for Totally Enclosed Type Induction Motor with Experimentally Verified CFD-Based MOGA Simulations

The energy efficient electric motors save energy thus reduce operating costs. Since there are several losses affecting the motor efficiency, fan design plays an important role to minimize these losses. This study examines the effects of the design parameters of a radial bladed fan on the motor efficiency in a 132 frame with a power of 7.5 kW. The parametric analysis was carried out with the computational fluid dynamics method, and the results were used for the multiobjective genetic algorithm (MOGA) optimization study with the highest efficiency and the lowest motor body temperature objectives. The hub height, hub radius, distance to body cover, blade rising angle, fan cover entrance distance, blade edge angle, blade center radius, blade edge radius, blade end radius, and center edge distance were selected as optimization parameters. 151 simulations were performed. The results showed that the most important parameter for fan efficiency is the hub height which is the parameter that determines the height of the fan impeller diameter. According to the results, the optimum fan design increased the efficiency by 8% compared to the original fan and reduced the winding temperature by 8 °C. The optimized fan design was manufactured and tested against imulation data. This study contributes to sustainable development goals by improving motor efficiency that reduces the cost, designing of new components, and cooling the fan effectively that reduces the amount of copper used.

Numerical analysis of machinability and surface alterations in cryogenic machining of additively manufactured Ti6Al4V alloy

Metal additive manufacturing (AM) technology has been utilized in many industries including automotive, aerospace, and medical. AM Ti6Al4V (Ti64) alloy is highly noticed for production of medical instruments such as dental implants and the machining process is mostly needed during the production or post-processing of these components. Numerical model, as a powerful tool, can be efficiently used for analyzing the machining process. A customized model was employed using a user-written subroutine in this work to evaluate machinability and microstructural changes in cryogenic machining of AM Ti64 alloy. For this purpose, the microstructural changes were simulated as the new numerical outputs. The numerical results of cutting forces, temperature, nano-hardness, and alpha lamellae thickness (grain size) were successfully verified by corresponding experiments from literature. Then, the impact of tool geometry (including rake and clearance angles, cutting edge radius, and nose radius) on the machinability performance was examined. It was found that, the variation of clearance and rake angles were more effective on depth of the hardened layer compared to the other parameters. Thickness of alpha lamellae phase near the machined surface and depth of the affected layer by nano-hardness changes were changed from 0.9 to 1.58 µm, and from 18 to 40 µm, respectively. Overall, it was concluded that the variation of insert positioning made by tool holder (change in rake and clearance angles) was an effective parameter on the process outputs when machining AM Ti64 alloy.

Experimental investigation on extrinsic size effect in micro-orthogonal cutting of commercial aluminium alloy

The achievable precision in micro-machining is constrained by a phenomenon known as the size effect. The edge radius of the tool significantly influences the size effect leading to non-proportional scaling of process performance. The process becomes unscalable below a certain ratio of uncut chip thickness to edge radius termed as critical relative tool sharpness (RTS). Despite extensive studies on the size effect associated with non-linear process performance, very limited studies have focused on the critical RTS range. In the present study, orthogonal cutting experiments were conducted on a commercial aluminium alloy (Al6060) with different cutting-edge radiuses in the RTS range of 0.5 to 0.01. Extensive analysis of the morphology of the chips and tool-work material adherence has been carried out and correlated with the observed size effect on surface integrity. One of the key findings in this study was the size effect in the chips with respect to the chip curl radius and pitch. Between RTS 0.5 and 0.09, an increase in chip curl and pitch is observed, followed by a sharp fall up to RTS 0.07. In addition, another notable phenomenon was the formation of dual-layered chips with deformed layer on the rake side and lamellae like features on the free side. Furthermore, size effect was observed in surface roughness, surface hardness and flank adherence. In summary, the present investigation offers a comprehensive understanding of the size effect within the critical RTS range elucidating its multifaceted impact on micro-cutting.

Advanced approach of forming cutting edge radii on cemented carbide cutting tools using plasma discharges in electrolyte

The paper deals with the task of preparing cutting edge microgeometry. Unconventional methods for edge preparation are presented, and an overview of articles, patents, and reports that deal with modern and advanced approaches are stated. Moreover, an innovative cutting edge preparation method using plasma discharges in an electrolyte was examined. The main aim was to determine the effect of the process parameters, namely electrolyte concentration, the temperature of the electrolyte, the voltage between electrodes and the operating time, on the shape and size of the cutting edge rounding as well as surface roughness and topography. The tested type of cutting tool was cutting insert. The cutting inserts were made of cemented carbide (WC + Co). It was examined that cutting edge radius sizes were strongly affected by the process parameter of plasma discharges in electrolyte as well as the shape of rounding. However, specific types of defects can occur on the cutting edge after edge preparation using plasma discharges in electrolyte. These defects can be avoided by correctly setting the process parameters. From the results of the experimental research, it was confirmed that cutting edges can be rounded without defects in the entire range of electrolyte concentration, but the setting of voltage and temperature of the electrolyte must be simultaneously considered. Furthermore, decreasing the electrolyte concentration, the temperature of the electrolyte and the voltage between electrodes resulted in a larger cutting edge radius. Cutting edge preparation using plasma discharges in electrolyte takes only a few seconds, depending on the cutting edge radius sizes. Cutting edge radii with a value of 20 μm were manufactured in 30 s. This innovative advanced edge preparation method is one of the most productive edge preparation methods. An even more important aspect is not to burden the environment with hazardous waste such as acids because this electrolyte solution can be prepared by dissolving a small amount of salt in tap water. The issue of the topography of the surface of cemented carbides after PDE treatment should be expecially heeded.