Materials
Processing
Technology
ELSEVIER Journal of Materials Processing Technology 61 (1996) 231-237
Abstract
The objective of this research is to use an analytical and experimental approach to develop new trends of cutting tool geometry with
negative Side Cutting Edge Angle (SCEA). The first task of this research is to conduct experimental tests for different SCEAs, cutting
speeds, feed rates and depths of cut. This is accomplished as follows. One set of these experimental results will be used as a feedback
to develop new empirical formulae required to predict cutting forces and other machining parameters. A second set of experimental tests
will be conducted in this study to ensure the validity of the empirical relationships associated with the mathematical model. The second
task is to develop a mathematical model to predict cutting forces for the three dimensional oblique cutting operation. New cutting tools
will be proposed by using the results of the expanded mathematical model.
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the empirical equations in this work. However, because of the insert clamped on tool holders to produce different SCEAs and
limited amount of experimental data due to the small variety of ECEAs. The proposed scheme of new inserts and tool holders
the tool inserts on the market, a combination of curve fitting, has the same dimensions and properties similar to the CNGM -
trend analysis, interpolation, and iteration of the computer 432 insert used in the research. ALso, the proposed scheme has
program using the theoretical equations of similar conditions have very good flexibility as each proposed insert could be used for
been considered to develop empirical equations using the seven operations similar to the 80 degree diamond-shaped insert
following steps: which has been used in the experiments. End Cutting Edge Angle
1. The existing equations for geometrical relationship of (ECEA) should not be less than 2.5 degree due to dynamic
oRhogonal cutting were used as the basis for developing the condition of metal cutting, as additional criteria imposed in the
empirical equations for geometrical parameters. designing process. The tool insert may be installed in different
2. The theoretical equations developed by Armarcgo [1] for toolholders with different SCEA's and ECEA's. The CNMG -432
cutting forces were used as basis equations to derive empirical insert and DCLNR, DCGNR, and DCRNR toolholders developed
equations for the cutting forces. However, these equations, arc by Kennametal have been used in this rcsearoh.
function of chip flow angle Vc, normal friction angle ~,, and In metal cutting, the occurrence of chattering and vibration
normal shear angle ~bn,which have been empirically developed as may be controlled by providing appropriate End Cutting Edge
functions of side cutting edge angles. These empirical equations Angle (ECEA) in the tool geometry design. The value of ECEA
arc vital in the mathematical model to predict the cutting forces. can directly affect surface finish, dimensional accuracy, and tool
Having the predicted values of these forces, then, it is possible to life. The ECEA is provided in tool design to prevent the
predict all other machining parameters. auxiliary cutting edge from cutting, scratching or rubbing,
3. The first estimate of SCEA was introduced as an independent thereby reducing the friction of the auxiliary flank on the
variable in the basis equations. The program was run to begin an machined surface of work-piece. In the case of negative $CEA
iterative operation in which the results of each run were compared with -5 ° the diamond angle has to be reduced. The smaller the
with the associated plotted curve. An acceptable deviation diamond angle is, the weaker the area surrounding the finishing
(_T10%) was set by iterativc operations. point of the insert. The experimental tests at large negative
4. The second independent variable (cutting speed V) was SCEA should be avoided due to a wedging action on the cutting
introduced into the empirical equations in the same manner. The edge that often causes severe edge breakage. The diamond angle
program was run to obtain an acceptable deviation (_T_10%) using may be increased by decreasing ECEA; however, the size of
both independent variables (SCEA and cutting speed) in each ECEA should not be less than 3" due to the dynamic condition of
equation. metal cutting. As ECEA is increased, the maximum roughness
In oblique cutting the cutting speed V, forms an angle with height R,,~ increases which means the quality of surface is
the plane normal to the cutting edge called the inclination angle expected to deteriorate. However, a reduction in ECEA increases
(i). The main cutting edge forms side cutting edge angle ~, and the radial force because the auxiliary cutting edge becomes more
the secondary edge forms the end cutting edge as shown in Figure active and may cause chattering and vibration. An ECEA angle
7 [1-6]. A mathematical model was designed to use the input of 5 ° to 15 ° has been found satisfactory in most tool design cases
parameters of tool geometry, tool material and work-piece [1].
material, cutting condition and machine specifications. The modal
has included mathematical relationships and empirical formulae 5. Conclusions and Remarks
developed for oblique cutting to calculate the main output
parameters of metal cutting such as; three cutting forces (feed, Direct experimental evidence shows that the values of all
tangential and radial), coefficient of friction, shear force, shear three curing forces (the main cutting or tangential, the feed and
energy, friction force, and friction energy. The model is designed the radial forces) wen: decreased as negative $CEA decreases
to run a wide range of input data to test the effect of side cutting below -5 °. The measurements of cutting forces for tool geometry
edge angle on the performance of cutting, quality of surface finish with SCEA of -17.5 ° indicated lower values than tool geometry
and cutting condition parameters. A computer program has bccn with SCEA of 0 ° and -5". The color of the chip root with SCEA
written for this model, tested and verified. A sample of the of-17.5 ° was light brown compared to the color of the chip with
output of the mathematical model is illustrated in Figures 8. For SCEA of 4..15" was a dark blue, which indicate lower cutting
more details of the mathematical model the reader should refer to temperature with SCEA of -17.5". However, the color of the
Kattan [27]. chip with $CEA of 4..45" was light blue and brown, which
indicates lower cutting temperature with SCEA of 4-45 °
4. The Proposed New Cutting Tools compared to the tool with $CEA of 4-15 °. The radial force has
increased for SCEA at 4..45° over the radial force at SCEA 4-15"
A new scheme of tool geometry with negative SCEA has but the magnitude of both the tangential and the feed forces were
been proposed. The following diamond-shaped inseRs with decreased sharply. These results arc consistent with all color of
diamond angles of 85 °, 75 °, 70 °, 65 ° and 60 ° have been the chips corresponding to the tool geometry with negative SCEA.
designed. Each tool insert may be installed in different tool The thickness of Secondary Shear Zone (SSZ) with cutting tool
holders to produce different SCEAs and ECEAs. Figure 9, with SCEA of-5" was less than the thickness of SSZ with cutting
shows the geometry of proposed inserts with respect to the tool has $CEA 0 °, another indicator for cutting temperature. The
workpicce material in the cutting operations. Table 1 illustrates temperature in the $SZ depends on the heat evolved and the heat
the proposed new tool geometry for different diamond-shaped dissipated. The specific heat evolved in the $SZ is proportional
1.A, Kattan, K,R. Currie/Journal of Materials Processing Technology 61 (1996) 231-237 235
Worksuriac~
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cut (d)
MAIN CUTTING
EDGE
X4
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FIGURE 5 THE FLOW LINES OF MJCROSTRUCTURE SCEA K - -25.00 SPEED V- 140.0 m/min
OF A CH~-ROOT AND T ~ TOOL TIP
THY.SE V A L U E S A R E C A L C U L A T E D BY THE MODEL
AND COMPARED WITH THE EXPERIMENTAL RESULTS
12.5"~_~ 10.0"
10.0"
t 2 .5"
to the shear deformation and the tangential force. The heat [12] Merchant, M.E., "Mechanics of the Metal Cutting Process.
dissipation conditions are basically determined by the curing I. Orthogonal Cutting and a Type 2 Chip," Journal of
speed, the depth of cut, the thermal conductivity of the workpiece Applied Physics, Vol. 16, No. 5, 1945, pp. 267-275.
material and the cooling system. The temperature of the moving [13] Lee, E. H., and Shaffer, B. W., "The Theory of Plasticity
surface of the chip depends on the heat generated along the lower Applied to a Problem of Machining," Journal of Applied
surface of the chip, the dissipation conditions and the heating of Mechanics, Vol. 22, Transaction ASME, Vol. 73, 1951,
the chip during plastic deformation in the chip formation zone. pp. 405-413.
The rate of the tool wear is generally observed to increase with [14] Stabler, G. N., "The Fundamental Geometry of Cutting
higher cutting temperature. Tools," Proceedings Institute of Mechanical Engineering,
The measurements of quality of surface finish show that the No. 63, 1951, p. 165.
highest quality of surface roughness, surface roundness, and [15] Usui, E., Hirota, A. and Masuko, M. "Analytical
waviness is obtained with a tool geometry having an SCEA angle Prediction of Three-Dimensional Cutting Process. Part 1
of-5 degrees. A relatively poor surface finish was obtained at an Basic Cutting Model and Energy Approach," Journal of
SCEA of + 15 degrees. This is due to the effect of high radial Engineering for Industry, Vol. 100, Transactions ASME,
force at + 15 degrees which made the tool work system less rigid 1978, pp. 222-228.
with more vibration and chattering. To verify the results on the [16] Usui, I., and Hirota, A. "Analytical Predication of Three
quality of surface finish, large samples with 210 readings for Dimensional Cutting Process. Part 2 Chip Formation and
twelve cutting conditions, at SCEA -5, 0.0, +15 degrees and Cutting Force with Conventional Single-Point Tool,"
cutting speeds 62, 94, 144 and 225 m/min, have been conducted Journal of Engineeringfor Industry, Vol. 100, Transactions
as a special case study to determine the quality of surface finish ASME, 1978, pp. 229-235.
using Process Capability Indices. The objective of this research [17] Usui, E., Shirakashi, T., and Kitagawa, T., "Analytical
is to better understand of oblique cutting process and the role of Prediction of Three-Dimensional Cutting Process. Part 3
new tool on the quality of surface finish and productivity of tool Cutting Temperature and Crater Wear of Carbide Tool,"
life. The other objectives of this study are to investigate the Journal of Engineeringfor lndustry , Vol. 100, Transcations
effect of negative SCEAs on machining parameters in the oblique ASME, 1978, pp. 236-243.
cutting process. This is a novel research and a new awareness of [18] Venu Vinod, P.K., Waishing Lau, and Barrow, G., "On a
designing tools with negative SCEAs and the influence of the new New Model of Oblique Cutting," Journal of Engineering
geometry on other machining parameters. forlndustry, Vol. 100, TransactionsASME, 1978, pp. 287-
292.
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