Understanding of cutting tool edge preparations and their impacts on machining process performance

Abstract

The cutting tool edge preparation is considered as one of the important technologies that were recently developed for micro-machining due to its impact on cutting forces and stresses, tool life, temperature distribution and surface integrity. The most frequent tool edge preparations include round edge, chamfered edge and sharp edge. It is not easy to determine, for a given workpiece material, the appropriate tool edge preparation or the machining parameters that should be used, as they are interrelated and affect jointly several machining performance indicators. The objective of this thesis is to conduct a research study on the effects of three cutting tool edge geometries and the cutting parameters on the machining characteristics such as cutting temperature, effective stress, chip thickness and tool wear. The cutting tool edge geometries studied are round, chamfer and sharp. This study consisted of simulating the orthogonal cutting process of AISI 1045 steel using 2D finite elements DEFORM software. The numerical simulation tests were performed using a design of experiments (DOE) based on Taguchi orthogonal array design which included different tool edge parameters such as nose radius, chamfer width, chamfer angle, sharp angle and the cutting parameters such as cutting speed, feed rate. This research work is divided into three stages. In the first stage, a 2D simulation model based on finite element analysis was developed to predict the effects of the tool nose radius with small and large scales and cutting parameters on cutting temperature, cutting stress and tool wear. The obtained results showed that cutting temperature, stress and tool wear presented approximately linear dependency with tool nose radius. In the second stage, numerical tests were performed to investigate the effects of chamfer width, chamfer angle, sharp angle, cutting speed, feed rate and their interactions on cutting temperature, effective stress and wear depth. The obtained results were evaluated statistically using analysis of variance (ANOVA). At the end, in the third stage, significant edge geometry factors and their interactions with machining parameters were determined; then, numerical simulation comparisons were made in order to determine the optimal parameters in order to get good cutting tool preparation between round, chamfer and sharp edges for a better cutting process performance.

Date	23 Aug 2024
Original language	American English
Awarding Institution	École de technologie supérieure
Supervisor	Victor Songmene (Supervisor) & Thien-My Dao (Co-supervisor)