Title: An experimental study on dead metal zone in orthogonal cutting with worn rounded-edge cutting tools

Authors: Alper Uysal; Sabri Ozturk; Erhan Altan

Addresses: Department of Mechanical Engineering, Yıldız Technical University, 34349, Istanbul, Turkey ' Department of Mechanical Engineering, Abant Izzet Baysal University, 14280, Bolu, Turkey ' Department of Mechanical Engineering, Yıldız Technical University, 34349, Istanbul, Turkey

Abstract: A dead metal zone is formed by the negative rake angle effect of the rounded-edge and it affects the cutting forces during machining operations. Therefore, investigating the size of the dead metal zone and changing it with cutting edge radius and flank wear rate are important. In this study, the dead metal zone was investigated experimentally for unworn and worn rounded-edge cutting tools and it was defined by changing the flank wear rate and cutting edge radius. It was observed that the size of the dead metal zone increased with increase of the cutting edge radius and it became smaller with increasing the flank wear rate. In addition, cutting force and thrust force were investigated. It was proven that both forces increased with increase of the cutting edge radius and the flank wear rate.

Keywords: dead metal zone; rounded-edge cutting tools; worn cutting tools; orthogonal cutting; cutting force; thrust force; tool wear; negative rake angle; cutting edge radius; flank wear rate.

DOI: 10.1504/IJMPT.2015.072574

International Journal of Materials and Product Technology, 2015 Vol.51 No.4, pp.401 - 412

Received: 14 May 2014
Accepted: 20 May 2015
Published online: 19 Oct 2015 *

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