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SURFACE FINISH AND TOOL WEAR CHARACTERIZATION IN HARD TURNING USING A MATHEMATICAL CUTTING TOOL REPRESENTATION

2011; Taylor & Francis; Volume: 15; Issue: 4 Linguagem: Inglês

10.1080/10910344.2011.620916

1532-2483

Raja Kountanya,

Advanced Surface Polishing Techniques

Abstract The development of a general 3D model for a corner-radiused, chamfered, edge-honed cutting worn tool is elaborated. The surface of the cutting tool was constructed using one angular scalar specifying location on the corner radius and leading/trailing edges and another non-dimensional scalar for specifying location on the relief, edge-hone, chamfer and tool-top. Then, for given geometric parameters and cutting conditions, the angular extremities of contact on the corner radius and leading/trailing edges was obtained and validated. The kinematic surface finish on the workpiece surface including the Brammertz and sideflow effects was then simulated in typical hard turning. The model was expanded to allow wiper edges and flank wear. A simplified crater wear model was adopted for continuous hard turning to allow virtual cross-sectioning. Accurate estimation of flank and crater wear volume was also enabled. The model results for the fresh tool agreed with well-known trends from 2D modeling. Preliminary results indicate that there exists a geometric basis for higher Ra and Rt for a worn tool. The Brammertz effect simulation, though not in agreement with the data of Knuefermann (Citation2003) corroborated the modification proposed therein. Keywords: edge honekinematichard turningsurface finishtool wear ACKNOWLEDGMENTS The author acknowledges the advice and guidance of his doctoral thesis advisor Prof. William Endres of Michigan Technological University and Gustavo Delfino, a former graduate student, whose term paper at University of Michigan provided the starting point and motivation for this work. Notes 1Mathematica is the registered trademark of Wolfram Research, Inc. The author presented an outline of the work in a recent conference (Kountanya, R., Citation2011. A Computer Model For Worn Cutting Edge In Hard Turning, Intertech 2011, Chicago, IL.). 2Wyko is the registered trademark of Veeco Instruments Inc. *Note: Currently with United Technologies Research Center, Process Modeler.