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

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.

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Fig. 1

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

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Fig. 2

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

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Fig. 3

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

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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

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Fig. 5

Variable wedge angle along the nose cutting edge

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Fig. 6

Cutting edge radius measurements

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Fig. 7

Flank wear development in longitudinal turning

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Fig. 8

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

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Fig. 9

Variable speed Taylor's tool life plot

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Fig. 10

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

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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

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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




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