Title: A numerical study of cutting edge radius effects on stress evolutions of diamond coated tools
Authors: Jianwen Hu, Y. Kevin Chou, Raymond G. Thompson
Addresses: Mechanical Engineering Department, The University of Alabama, 290 Hardaway Hall, 7th Ave., Tuscaloosa, AL 35487, USA. ' Mechanical Engineering Department, The University of Alabama, 290 Hardaway Hall, 7th Ave., Tuscaloosa, AL 35487, USA. ' Vista Engineering, Inc., 2500 1st Ave. N., Suite B117, Birmingham, AL 35203, USA
Abstract: The stress state of a diamond coated tool is interrelatedly influenced by coating and subsequent machining. Moreover, the cutting edge geometry strongly impacts the stress fields around the tool tip in both processes. In this study, finite element modelling and cutting simulations were applied to investigate stress evolutions in a coated tool from deposition to machining, with the edge radius effect emphasised. For the deposition residual stress, edge sharpness results in significant stress concentrations at the edge rounding area. In machining, the thermal load is more dominant to the stress evolutions than the mechanical load. Increasing the edge radius generally results in increased stress reversal. Moreover, the edge hone effects on stress reversal are more prominent at a small uncut chip thickness. Since the edge radius has conflicting effects on the deposition stresses and machining loads, there may exist an optimal edge radius for the tool stress conditions.
Keywords: cutting tools; deposition stresses; diamond coating tooling; edge radius; machining; cutting edge geometry; finite element method; modelling; cutting simulation; thermal load; edge radius.
International Journal of Machining and Machinability of Materials, 2010 Vol.7 No.3/4, pp.149 - 160
Published online: 07 May 2010 *Full-text access for editors Full-text access for subscribers Purchase this article Comment on this article