Journal of the Korean Society for Precision Engineering (한국정밀공학회지)

Korean Society for Precision Engineering (한국정밀공학회)
권호 표지
DOI QR코드

DOI QR Code

Physically Compatible Characteristic Length of Cutting Edge Geometry

공구날 특이길이의 물리적 적합성 고찰

  • Ahn, Il-Hyuk (Productivity Research Institute, LG Electronics Inc.) ;
  • Kim, Ik-Hyun (Graduate School of NID Fusion Technology, Seoul Nat'l Univ. of Sci. & Tech.) ;
  • Hwang, Ji-Hong (Dept. of Product Design & Manufacturing Eng., Seoul Nat'l Univ. of Sci. & Tech.)
  • 안일혁 (LG전자 생산기술원) ;
  • 김익현 (서울과학기술대학교, NID융합기술대학원) ;
  • 황지홍 (서울과학기술대학교, 제품설계금형공학과)
  • Received : 2011.08.16
  • Accepted : 2011.11.06
  • Published : 2012.03.01
Download PDF
⟨ Previous Next ⟩

Abstract

The material removal mechanism in machining is significantly affected by the cutting edge geometry. Its effect becomes even more substantial when the depth of cut is relatively small as compared to the characteristic length which represents the shape and size of the cutting edge. Conventionally, radius or focal length has been employed as the characteristic length with the assumption that the shape of cutting edge is round or parabolic. However, in reality, there could be various ways to determine the radius or focal length even for the same tool edge profile, depending on the region to be considered as cutting edge in the measured profile and the constraints to be set in constructing the best fitted circle or parabola. In this regard, the present study proposes various models to determine the characteristic length in terms of radius or focal length. Their physical compatibility are validated by carrying out 2D orthogonal cutting experiments using inserts with a wide range of characteristic length ($30{\sim}180\;{\mu}m$ in terms of radius) and then by investigating the correlation between the characteristic length and the cutting forces. Such validation is based on the common belief that the larger the characteristic length is, the blunter the cutting edge is and the higher the cutting forces are. Interestingly, the results showed that the correlation is higher for the radius or focal length obtained with a constraint that the center of best fitted circle or the focus of the best fitted parabola should be on the bisectional line of the wedge angle of tool.

Keywords

References

  1. Yen, Y. C., Jain, A. and Altan, T., "A Finite Element Analysis of Orthogonal Machining Using Different Tool Edge Geometries," Journal of Materials Processing Technology, Vol. 146, No. 1, pp. 72-81, 2004. https://doi.org/10.1016/S0924-0136(03)00846-X
  2. Woon, K. S., Rahman, M., Fang, F. Z., Neo, K. S. and Liu, K., "Investigations of Tool Edge Radius Effect in Micromachining: A FEM Simulation Approach," Journal of Materials Processing Technology, Vol. 195, No. 1-3, pp. 204-211, 2008. https://doi.org/10.1016/j.jmatprotec.2007.04.137
  3. Liu, K. and Melkote, S. N., "Finite Element Analysis of the Influence of Tool Edge Radius on Size Effect in Orthogonal Micro-Cutting Process," International Journal of Mechanical Sciences, Vol. 49, No. 5, pp. 650-660, 2007. https://doi.org/10.1016/j.ijmecsci.2006.09.012
  4. M'Saoubi, R. and Chandrasekaran, H., "Investigation of the Effects of Tool Micro-Geometry and Coating on Tool Temperature during Orthogonal Turning of Quenched and Tempered Steel," International Journal of Machine Tool and Manufacture, Vol. 44, No. 2-3, pp. 213-224, 2004. https://doi.org/10.1016/j.ijmachtools.2003.10.006
  5. Childs, T. H. C., Dornfeld, D., Lee, D. E., Min, S., Sekiya, K., Tezuka, R. and Yanmane, Y., "The Influence of Cutting Edge Sharpness on Surface Finish in Facing with Round Nosed Cutting Tools," CIRP Journal of Manufacturing Science and Technology, Vol. 1, No. 2, pp. 70-75, 2008. https://doi.org/10.1016/j.cirpj.2008.09.001
  6. Asai, S., Horio, K., Kasai, T. and Kobayashi, A., "Measuring the Very Small Cutting Edge Radius for a Diamond Tool Using a New Kind of SEM Having Two Detectors," Annals of the CIRP, Vol. 39, No. 1, pp. 85-88, 1990. https://doi.org/10.1016/S0007-8506(07)61008-7
  7. Ogivie, A. and Chou, K., "Cutting Edge Profile Characterizations by White-Light Interferometry," 2009 ASME Early Career Technical Conference, pp. 19.1-19.8, 2009.
  8. Ranganath, S., Hwang, J. and Campbell, A. B., "Experimental Investigation and Mechanistic Modeling of the Effects of Tool Edge Hone Effects in Turning Operations," 2005 ASME International Mechanical Engineering Congress and Exposition, pp. 833-842, 2005.
  9. Hwang, J. and Chandrasekar, S., "Contact Conditions at the Chip-Tool Interface in Machining," International Journal of Precision Engineering and Manufacturing, Vol. 12, No. 2, pp. 183-193, 2011. https://doi.org/10.1007/s12541-011-0026-7
  10. Devore, J. L., "Probability and Statistics for Engineering and the Sciences," Duxbury Press, pp. 474-585, 1995.
  11. Backer, W. R., Marshall, E. R. and Shaw, M. C., "The size effect in metal cutting," Transactions of the ASME, Vol. 74, No. 1, pp. 61-72, 1952.
  12. Madhavan, V., Chandrasekar, S. and Farris, T. N., "Machining as a Wedge Indentation," Journal of Applied Mechanics, Vol. 67, No. 1, pp. 128-139, 2000. https://doi.org/10.1115/1.321157
  13. Hutchings, I. M., "Deformation of Metal Surfaces by the Oblique Impact of Square Plates," International Journal of Mechanical Sciences, Vol. 19, No. 1, pp. 45-52, 1977. https://doi.org/10.1016/0020-7403(77)90015-7

Cited by

  1. A mechanistic cutting force model with consideration of the intrinsic and geometric size effects decoupled vol.81, pp.5-8, 2015, https://doi.org/10.1007/s00170-015-7227-7
  2. An efficient way of investigating the intrinsic size effect in machining vol.230, pp.9, 2016, https://doi.org/10.1177/0954405415612378
  3. Characteristic length of the solidified melt pool in selective laser melting process vol.23, pp.2, 2017, https://doi.org/10.1108/RPJ-06-2015-0076