0
Research Papers

Design for Manufacturing of Variable Microgeometry Cutting Tools

[+] Author and Article Information
N. Z. Yussefian

Sandvik Coromant Research and Development,
Lerkrogsvägen 19,
Hägersten, Stockholm SE12680, Sweden
e-mail: nima.zarifyussefian@sandvik.com

A. Hosseini

Mem. ASME
Machining Research Laboratory (MRL),
Faculty of Engineering and Applied Science,
University of Ontario Institute of
Technology (UOIT),
Oshawa, ON L1H 7K4, Canada
e-mail: Sayyedali.hosseini@uoit.ca

K. Hosseinkhani

Department of Mechanical Engineering,
McMaster University,
1280 Main Street West,
Hamilton, ON L8S 4L7, Canada
e-mail: hosseik@mcmaster.ca

H. A. Kishawy

Fellow ASME
Machining Research Laboratory (MRL),
Faculty of Engineering and
Applied Science,
University of Ontario Institute of
Technology (UOIT),
Oshawa, ON L1H 7K4, Canada
e-mail: Hossam.kishawy@uoit.ca

1Corresponding author.

Manuscript received March 29, 2017; final manuscript received September 21, 2017; published online November 17, 2017. Assoc. Editor: Guillaume Fromentin.

J. Manuf. Sci. Eng 140(1), 011014 (Nov 17, 2017) (7 pages) Paper No: MANU-17-1182; doi: 10.1115/1.4038206 History: Received March 29, 2017; Revised September 21, 2017

Cutting edge microgeometry has gained special attention of late in the machining research community. Machine tool vibration, tool life, and workpiece surface integrity are all influenced by cutting edge size/shape. To optimize the machining process, variable microgeometry (VMG) cutting tools, in which the edge microgeometry varies along the edgeline with respect to specific variables (such as machining parameters or expected tool wear), are manufactured. Despite the advantages of VMG tools, a major hindrance in their development is the manufacturing complexity that demands high precision multi-axis edge preparation processes following extensive machine setup, fixturing, and programming. This paper details the proof of concept of a design criterion, which leads to the manufacturing of VMG cutting tools by only traditional edge preparation processes. The present method relies on the existing relationship between the edge radius subsequent to the edge preparation process and the tool wedge angle. The validity of the proposed method is first examined by a numerical simulation of the edge preparation. Carbide cutting tool inserts are then designed based on the proposed idea. Robust VMG generation subsequent to edge preparation by microblasting is demonstrated through microgeometric measurements. VMG chemical vapor deposition-coated carbide tools manufactured by the proposed approach are evaluated for turning hardened steel, and optimal designs are identified with respect to tool life and workpiece surface roughness. To address the design consideration, finite element (FE) modeling provides valuable insight into the machining process. FE modeled stress and temperature distribution clarify the experimental observations and reveal the design constraints.

FIGURES IN THIS ARTICLE
<>
Copyright © 2018 by ASME
Your Session has timed out. Please sign back in to continue.

References

Nasr, M. N. A. , Ng, E.-G. , and Elbestawi, M. A. , 2007, “ Modelling the Effects of Tool-Edge Radius on Residual Stresses When Orthogonal Cutting AISI 316 L,” Int. J. Mach. Tools Manuf., 47(2), pp. 401–411. [CrossRef]
Ventura, C. H. H. , Köhler, J. , and Denkena, B. , 2015, “ Influence of Cutting Edge Geometry on Tool Wear Performance in Interrupted Hard Turning,” J. Manuf. Processes, 19, pp. 129–134. [CrossRef]
Bassett, E. , Köhler, J. , and Denkena, B. , 2012, “ On the Honed Cutting Edge and Its Side Effects During Orthogonal Turning Operations of AISI1045 With Coated WC-Co Inserts,” CIRP J. Manuf. Sci. Technol., 5(2), pp. 108–126. [CrossRef]
Denkena, B. , Lucas, A. , and Bassett, E. , 2011, “ Effects of the Cutting Edge Microgeometry on Tool Wear and Its Thermomechanical Load,” CIRP Ann., 60(1), pp. 73–76. [CrossRef]
Denkena, B. , Köhler, J. , and Bergmann, B. , 2015, “ Development of Cutting Edge Geometries for Hard Milling Operations,” CIRP J. Manuf. Sci. Technol., 8, pp. 43–52. [CrossRef]
Klocke, F. , and Kratz, H. , 2005, “ Advanced Tool Edge Geometry for High Precision Hard Turning,” CIRP Ann., 54(1), pp. 47–50. [CrossRef]
Özel, T. , Karpat, Y. , and Srivastava, A. , 2008, “ Hard Turning With Variable Microgeometry PcBN Tools,” CIRP Ann., 57(1), pp. 73–76. [CrossRef]
Yussefian, N. Z. , and Koshy, P. , 2016, “ Geometric Simulation of Electro-Erosion Edge Honing: Insights Into Process Mechanisms,” Precis. Eng., 48, pp. 1–8. [CrossRef]
Armarego, E. J. A. , and Brown, R. H. , 1969, The Machining of Metals, Prentice Hall, Englewood Cliffs, NJ.
Hosseinkhani, K. , and Ng, E. , 2013, “ Analysis of the Cutting Mechanics Under the Influence of Worn Tool Geometry,” 14th CIRP Conference on Modeling of Machining Operations (CMMO), Turin, Italy, June 13–14, pp. 117–122.
König, W. , Langhammer, K. , and Schemmel, H.-U. , 1972, “ Correlations Between Cutting Force Components and Tool Wear,” CIRP Ann. Manuf. Technol., 21(1), pp. 19–20.

Figures

Grahic Jump Location
Fig. 1

(a) General macrogeometry of a cutting tool wedge and (b) cutting edge microgeometry by removing Ac from the sharp edge

Grahic Jump Location
Fig. 2

Cutting edge radius under various material removal from the edges as a function of wedge angle (r0=5μm)

Grahic Jump Location
Fig. 3

Comparison between resultant cutting edge radius (rβ) under constant removal for different wedge angles (β)

Grahic Jump Location
Fig. 4

Validation of the existing relationship between cutting edge radius and wedge angle by EE-honing simulation for different removals during the edge preparation process

Grahic Jump Location
Fig. 5

Variable wedge angle along the nose cutting edge

Grahic Jump Location
Fig. 6

Cutting edge radius measurements

Grahic Jump Location
Fig. 7

Flank wear development in longitudinal turning

Grahic Jump Location
Fig. 8

Tool wear progression, v=240m/min,f=0.12mm/rev, DOC=1mm

Grahic Jump Location
Fig. 9

Variable speed Taylor's tool life plot

Grahic Jump Location
Fig. 10

Surface roughness measurements by WLI on workpiece surface machined by different VMG tools, v=240m/min,f=0.10mm/rev, DOC=1mm

Grahic Jump Location
Fig. 11

Contours of min. in-plane principal stress for the cutting edge profile at the center of the nose (position s2) in longitudinal turning of AISI 4140 with workpiece hardness = 40–42 HRC, v=240 m/min, f=0.095 mm/rev, DOC=1.0 mm

Grahic Jump Location
Fig. 12

Contours of temperature distributions on tool-chip contact face for the cutting edge profile at the center of thenose (position s2) in longitudinal turning of AISI 4140 withworkpiece hardness = 40–42 HRC, v=240m/min,f=0.095mm/rev, DOC=1.0mm

Tables

Errata

Discussions

Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In