IJAT Vol.7 No.3 pp. 329-336
doi: 10.20965/ijat.2013.p0329


Analytical Approach for Optimization of Chamfered Cutting Tool Preparation Considering Built-Up Edge Extrusion Behavior

Hiroki Kiyota, Fumihiro Itoigawa, Shota Endo,
and Takashi Nakamura

Nagoya Institute of Technology, Gokiso-cho, Showa-ku, Nagoya, Aichi 466-8555, Japan

December 13, 2012
March 11, 2013
May 5, 2013
chamfered cutting tool, built-up edge, analytical model, depth-of-cut notch wear, Inconel718

A built-up edge (BUE) that is formed adjacent to a chamfered cutting edge is extruded along the cutting edge, if the appropriate chamfer geometry is selected. If a sharper BUE is stably extruded with high fluidity, notch wear at the depth-of-cut line and adhesion of the work material can be prevented. In this study, an analytical cutting model considering the BUE extrusion with a chamfered tool is proposed in order to optimize the chamfer preparation, i.e., chamfer angle and coefficient of friction between the chamfer face and the BUE, for the advantages of BUE extrusion. In this analysis, an empirical cutting model employing the slip-line field method and a BUE extrusion model using the slab method are coupled by static mechanics equilibrium. By coupling the two models, the shape of the BUE is uniquely determined. The calculated and experimental results in terms of actual rake angle and cutting force are roughly in agreement. The analytical results indicate that sharpness and the fluidity in the BUE extrusion can be simultaneously attained by preparing the tool with chamfer angle in which the material stagnation proceeds until the actual rake angle is equal to the rake angle of the tool.

Cite this article as:
Hiroki Kiyota, Fumihiro Itoigawa, Shota Endo, and
and Takashi Nakamura, “Analytical Approach for Optimization of Chamfered Cutting Tool Preparation Considering Built-Up Edge Extrusion Behavior,” Int. J. Automation Technol., Vol.7, No.3, pp. 329-336, 2013.
Data files:
  1. [1] K. Okushima and K. Hosomi, “The Side-flow of Metal in Machining (II. In the Case of Three-dimensional Cutting),” J. of JSPE, Vol.24, No.283, pp. 470-475, 1958.
  2. [2] Y. K. Chou, C. J. Evans, and M. M. Barash, “Experimental investigation on cubic boron nitride turning of hardened AISI 52100 steel,” J. of Mat. Proc. Tech., Vol.134, pp. 1-9, 2003.
  3. [3] B. A. Khidhir and B. Mohamed, “Study of cutting speed on surface roughness and chip formation when machining nickel-based alloy,” J. of Mech. Sci. and Tech., Vol.24, No.5, pp. 1053-1059, 2010.
  4. [4] X. Maohua, H. Ning, and L. Liang, “Modeling Notch wear of Ceramic Tool in High Speed Machining of Nickel-based Superalloy,” J ofWuhan U. of Tech. – Mat. Sci. Edition, Vol.25, No.1, pp. 78-83, 2010.
  5. [5] H. Kiyota, F. Itoigawa, A. Kakihara, and T. Nakamura, “Prevention of Depth-of-cut Notch Wear in CBN Tool Edge by Controlling the Built-up Edge,” Int. J. of Auto. Tech., Vol.5, No.3, pp. 342-348, 2011.
  6. [6] H. Kiyota, F. Itoigawa, and T. Nakamura, “Control of Built-up Edge Behavior by Chamfered Cutting Edge Preparation and Surface Modification,” Key Engineering Materials, Vols.523-524, pp. 1029-1034, 2012.
  7. [7] A. Kakihara, F. Itoigawa, H. Kiyota, and T. Nakamura “Stability of BUE in Cutting of Inconel718 and Restrain Effect on Tool Wear,” Proc. of 4th CIRP Int. Conf. on High Performance Cutting, pp. 191-196, 2010.
  8. [8] E. Usui and K. Hoshi, “Study on Tools with Restricyed Tool-Chip Contact Length (Part 4) (Natural and Cut-Away Tool’s Built-Up Edges),” JSPE, Vol.30, No.3, pp. 273-284, 1964.
  9. [9] T. Hoshi, “Machining Performance of High-Rate Face-Milling Cutters with SWC Application,” CIRP Ann.-Manuf. Tech., Vol.32, No.1, pp. 11-16, 1983.
  10. [10] C.-S. Chang and K.-H. Fuh, “An Experimental Study of the Chip Flow of Chamfered Main Cutting Edge Tools,” J. of Materials Processing Technology, Vol.73, No.1-3, pp. 167-178, 1998.
  11. [11] N. Fang, “Machining with tool-chip contact on the tool secondary rake face (Part I: a new slip-line model),” Int. J. of Mechanical Sciences, Vol.44, pp. 2337-2354, 2002.
  12. [12] N. Fang, “Slip-line modeling of machining with a rounded-edge tool (Part I: new model and theory),” J. of the Mechanics and Physics of Solids, Vol.53, pp. 715-742, 2003.
  13. [13] W. Johnson, “Some slip-line fields for swaging or expanding, indenting, extruding and machining for tools with curved dies,” Int. J. Mech. Sci., Vol.4, pp. 323-347, 1962.
  14. [14] E. Usui and K. Kikuchi, “Study on Tools with Restricyed Tool-Chip Contact Length (Part 1) (Theory of Plasticity Applied to Machining Mechanism),” JSPE, Vol.29, No.6, pp. 436-443, 1963.
  15. [15] H. Kudo, “Some new slip-line solutions for two-dimensional steady-state mchining,” Int. J. Mech. Sci., Vol.7, pp. 43-55, 1965.
  16. [16] N. Fang, “Tool-chip friction in machining with a large negative rake angle tool,” Wear, Vol.258, pp. 890-897, 2005.
  17. [17] P. L. B. Oxley and M. J. M.Welsh, “An Explanation of the Apparent Bridgeman Effect in Merchant’s Orthogonal Cutting Results,” J. of Engineering for Industry, Vol.89, pp. 549-555, 1967.
  18. [18] H.-H. Hsu and G.-Y. Tzou, “Two analytical models of double-layer clad sheet compression forming based on the upper bound and the slab methods,” J. of Materials Processing Technology, Vol.140, pp. 604-609, 2003.
  19. [19] Y.-M. Hwang and G.-Y. Tzou, “An analytical approach to asymmetrical cold- and hot-rolling of clad sheet using the slab method,” J. of Materials Processing Technology, Vol.62, pp. 249-259, 1996.

*This site is desgined based on HTML5 and CSS3 for modern browsers, e.g. Chrome, Firefox, Safari, Edge, Opera.

Last updated on Mar. 05, 2021