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Effect of edge preparation technologies on cutting edge properties and tool performance

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Abstract

Edge preparation has gained widespread use due to its low cost and high impact. Various edge preparation methods are reported in the literature. Choice of edge preparation techniques influences the edge properties and the ensuing tool performance. The current work investigates the influence of three different edge preparation methods, brushing, drag finishing, and wet abrasive jet machining on the performance of tungsten carbide inserts during orthogonal turning. Edge preparation not only changes the geometry but also the properties of the edge. Experimental results show that a drag finished edge has the lowest edge surface roughness (Ra = 0.42 μm), while abrasive jet machining can induce 63% greater compressive residual stress than the unprepared tool. Reduction in tool wear was observed at the same stage of cutting length in the prepared edges alongside improved edge hardness. A thermomechanical finite element analysis is performed to evaluate the thermomechanical behavior of all the cutting edges. Results demonstrate that the use of prepared cutting edges enhances stress distribution and reduces the temperature. Experimental results confirm that the drag finished edge has the best overall performance out of the three edge techniques with lower cutting temperature, better stress distribution, lower cutting forces, reduced flank wear, and reduced roughness of the machined surface finish.

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Acknowledgments

The authors are thankful to BERKS Machine Tools, Ontario, Canada, for preparing brushing and drag finishing samples and Institute of Machining Technology, Technische Universität Dortmund, Germany, for preparing wet abrasive jet machining samples.

Funding

This research was supported by Natural Sciences and Engineering Research Council of Canada (NSERC) under the CANRIMT Strategic Research Network Grant NETGP 479639-15.

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Authors and Affiliations

  1. Department of Mechanical Engineering, McMaster Manufacturing Research Institute (MMRI), McMaster University, 1280 Main Street West, Hamilton, ON, L8S4L7, Canada

    Wanting Wang, Md Khalid Saifullah, A. F. M. Arif & S. C. Veldhuis

  2. Institute of Machining Technology, Technische Universität Dortmund, Baroper Straße 303, 44227, Dortmund, Germany

    Robert Aßmuth & Dirk Biermann

Authors
  1. Wanting Wang
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  2. Md Khalid Saifullah
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  3. Robert Aßmuth
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  5. A. F. M. Arif
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  6. S. C. Veldhuis
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Correspondence to A. F. M. Arif.

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Wang, W., Saifullah, M.K., Aßmuth, R. et al. Effect of edge preparation technologies on cutting edge properties and tool performance. Int J Adv Manuf Technol 106, 1823–1838 (2020). https://doi.org/10.1007/s00170-019-04702-1

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  • DOI: https://doi.org/10.1007/s00170-019-04702-1

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