Chip Formation With Chamfered Tools

Hirao, Masatoshi; Tlusty, J.; Sonntag, Robert; Chandra, Garimella Raghu

doi:10.1115/1.3185839

Cited by 24 publications

(17 citation statements)

References 0 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…However, it may be observed in the figures that the lower portion of the tool in flank area is not filled by the DMZ. This fact is supported by experimental works of Hiaro et al [12]. Furthermore, it can be seen that the work material velocity increases from almost stagnation around the DMZ to the work velocity under the tool flank indicating a large degree of straining at this region that is not protected by DMZ.…”

Section: Simulation Proceduressupporting

confidence: 66%

FEM analysis of edge preparation for chamfered tools

Khalili

Safaei

2009

Int J Mater Form

View full text Add to dashboard Cite

The chamfer enhances the performance of the tool by strengthening the edge and reducing the possibility of tool wear and breakage. The strength of the chamfered tool can be investigated by analysis of process variables. This research investigates the effects of chamfer width and chamfer angle on process variables (force, stress, tool temperature and tool stress) in machining of a mild carbon low alloy steel by a cemented carbide tool using finite element method. The simulations show that the dead metal zone created under the tool acts as the effective cutting edge of the tool and increases the cutting forces. The predicted results show that the effect of chamfer width and angle is more pronounced on the thrust force than the cutting force. It also investigates the effect of chamfer on the effective shear angle and chip thickness, and comparison with available experimental results is presented. Tool temperatures are also predicted which suggests the presence of an optimum chamfer angle from the viewpoint of maximum tool temperature

show abstract

Section: Simulation Proceduressupporting

confidence: 66%

FEM analysis of edge preparation for chamfered tools

Khalili

Safaei

2009

Int J Mater Form

View full text Add to dashboard Cite

show abstract

“…6, which increases the tool edge strength and reduces the tool wear. 61 The cutting tool edge geometry, which means the chamfer angle, chamfer width and edge hone has a significant influence on tool life and to a large extent determines the surface finish and surface integrity of the machined part. Tool wear, on both flank and rake face constitutes a change in edge geometry.…”

Section: Effect Of Cbn Tool Cutting Edge Geometrymentioning

confidence: 99%

Tool wear, chip formation and workpiece surface issues in CBN hard turning: A review

Dogra

Sharma

Sachdeva

et al. 2010

Int. J. Precis. Eng. Manuf.

121

View full text Add to dashboard Cite

Steel parts that carry critical loads in everything from automotive drive trains and jet engines to industrial bearings and metal-forming machinery are normally produced by a series of processes, including time-consuming and costly grinding and polishing operations. Due to the advent of super-hard materials such as polycrystalline cubic boron nitride (PCBN) cutting tools and improved machine tool designs, hard turning has become an attractive alternative to grinding for steel parts. The potential of hard turning to eliminate the costs associated with additional finishing processes in conventional machining is appealing to industry. The objective of this paper, is to survey the recent research progress in hard turning with CBN tools in regard of tool wear, surface issues and chip formation. A significant pool of CBN turning studies has been surveyed in an attempt to achieve better understanding of tool wear, chip formation, surface finish, white layer formation, micro-hardness variation and residual stress on the basis of varying CBN content, binder, tool edge geometry, cooling methods and cutting parameters. Further important modeling techniques based on finite element, soft computing and other mathematical approaches used in CBN turning are reviewed. In conclusion, a summary of the CBN turning and modeling techniques is outlined and the scope of future work is presented.

show abstract

“…Tools with chamfered edge are used for machining hard materials due to their high edge strength. Chamfered cutting tool traps the work material over the chamfered edge and the formed dead metal acts like a cutting edge, which increases the tool edge strength and reduces the tool wear [13]. Author reported that residual stresses generated by large edge hone tools are typically more compressive than stresses produced by small edge hone tools and they also leave white-layers.…”

Section: Tool Edge (Curvilinear Edge/ Wiper Geometry)mentioning

confidence: 99%

Untitled

2011

JESTR

View full text Add to dashboard Cite

The effect of cutting tool geometry has long been an issue in understanding mechanics of turning. Tool geometry has significant influence on chip formation, heat generation, tool wear, surface finish and surface integrity during turning. This article presents a survey on variation in tool geometry i.e. tool nose radius, rake angle, groove on the rake face, variable edge geometry, wiper geometry and curvilinear edge tools and their effect on tool wear, surface roughness and surface integrity of the machined surface. Further modeling and simulation approaches on tool geometry including one approach developed in a recent study, on variable micro-geometry tools, is discussed in brief.Keywords: Curvilinear edge, rake angle, grooved tools, nose radius, variable geometry. Stringent control on the quality of machined surface and sub-surface during turning is most important consideration a part from considering the tool life. In order to attain sufficiently high production rates at minimum cost, optimization of cutting tool geometry is necessary [1], [2]. The design of cutting edge geometry and its influence on machining performance have been a research topic in metal cutting for a long time. Edge preparation has a critical effect on the tool life. A tool with poor edge preparation may chip and fail quickly [3]. Users expect to have more and more productivity in their machining processes (high removal rate of work-material) and low wear of their cutting tools (long tool life). These demands require major improvements in the design of cutting tools: new substrates, new coatings, cutting tool geometry and materials etc. According to tool manufacturers, the manufacturing procedures of their cutting tools, especially the micro-geometry preparation (cutting edge etc.), have a major influence on their performance and on their reliability [4]. Edge preparation must be carefully selected for a given application because it affects the surface integrity of the machined workpiece (white layer, residual stresses etc.) [5]. Heat generated during hard turning is also affected by edge preparation due to change in work material flow around the cutting edge. For example, a chamfered face provides excessive negative angle to the cutting action and results in high heat generation. PCBN tools rapidly wear out during hard turning at high cutting speeds mainly due to attained temperatures [6].It is important to consider the tool-edge effect in order to better understand the chip formation mechanism and accurately predict machining performances, such as cutting forces, cutting temperatures, tool wear, surface finish and the machined surface integrity. The methods commonly employed include experimental, analytical, and numerical methods [7]. The tool geometry effects on turning performance parameters are mentioned in Figure1.It is demonstrated that the cutting tool edge geometry significantly influences many fundamental aspects such as cutting forces, chip formation, cutting temperature, tool wear, tool-life and characteristics like sur...

show abstract

Chip Formation With Chamfered Tools

Cited by 24 publications

References 0 publications

FEM analysis of edge preparation for chamfered tools

FEM analysis of edge preparation for chamfered tools

Tool wear, chip formation and workpiece surface issues in CBN hard turning: A review

Untitled

Contact Info

Product

Resources

About