Flank Wear of Edge-Radiused Cutting Tools Under Ideal Straight-Edged Orthogonal Conditions

[+] Author and Article Information
Raja K. Kountanya

Dept. of Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125

William J. Endres

Dept. of Mechanical Engg.–Engg. Mechanics, Michigan Technological University, Houghton, MI 49931-1295e-mail: wjendres@mtu.edu

J. Manuf. Sci. Eng 126(3), 496-505 (Sep 07, 2004) (10 pages) doi:10.1115/1.1765148 History: Received January 01, 2004; Online September 07, 2004
Copyright © 2004 by ASME
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Dependence of cut-in wear on edge radius
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Unit force versus flank-wear land length: (top) up-sharp, (middle) moderate edge radius, and (bottom) large edge radius: (a) cutting direction, (b) thrust direction
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Evolving geometry of a flank-worn, edge-radiused tool (annotation shows relative boundary of the fresh tool); rn=125 μm,h=38 μm
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Evolving geometry of a flank-worn, edge-radiused tool (annotation shows relative boundary of the fresh tool); rn=70 μm,h=70 μm
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Geometry of an edge-radiused tool with a flank wear land
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Nondimensional wear-land depth versus length for zero rake and 11 deg clearance
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Blunt tool unit thrust force versus nondimensional wear-land length
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Blunt-tool unit force, per nondimensional wear-land length, versus non-dimensional wear-land length
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Experimental apparatus: (a) schematic of entire setup, (b) photo of work zone, (c) photo of main tool and borescope used for flank wear measurement
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Sample edge cross-section as viewed under optical microscope at 100×
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Flank-wear land length evolution: (top) up-sharp, (middle) moderate edge radius, and (bottom) large edge radius
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Effect of edge radius and wear-land on unit forces: (a) fresh-tool edge radius effect, (b) parasitic wear-land force for no edge radius
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Nonlinear regression result (thrust) for the all-at-once fit to the proposed functional form
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Percent deviation of piece-by-piece model relative to all-at-once model
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Edge-sharpening to an equivalent wear-land lw while not introducing the parasitic wear-land force: (a) sharpening procedure, (b) an actual edge
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Wear-sharpening factor computed from edge-sharpening experiment showing proposed exponential model and a regression-fit exponential



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