Authors: Y. Karpat, T. Ozel
Addresses: Department of Industrial Engineering, Bilkent University, Ankara 06800, Turkey. ' Department of Industrial and Systems Engineering, Rutgers University, Piscataway, NJ 08854, USA
Abstract: In this paper, uniform and variable edge microgeometry design inserts are utilised and tested for 3D turning process. In 3D tool engagement with workpiece, thickness of the chip varies from a maximum equal to the feed rate (at primary cutting edge) to a minimum on the tool|s corner radius (at trailing cutting edge). The ideal tool edge preparation should posses a variable configuration which has larger edge radius at the primary cutting edge than at the trailing cutting edge. Here the key parameter is the ratio of uncut chip thickness to edge radius. If a proper ratio is chosen for given cutting conditions, a variable cutting edge along the corner radius can be designed or |engineered|. In this study, Finite Element Modelling (FEM)-based 3D process simulations are utilised to predict forces and temperatures on various uniform and variable edge microgeometry tools. Predicted forces are compared with experiments. The temperature distributions on the tool demonstrate the advantages of variable edge microgeometry design.
Keywords: variable edge microgeometry; tool design; 3D turning; FEM; finite element method; modelling; PCBN inserts; chip thickness; edge radius; temperature distribution.
International Journal of Machining and Machinability of Materials, 2008 Vol.4 No.1, pp.26 - 38
Published online: 24 Oct 2008 *Full-text access for editors Full-text access for subscribers Purchase this article Comment on this article