A novel approach to cutting tool edge design based on initial wear stage

Cutting tool geometries play an important role in tool performance, material flow, cutting force, and cutting temperature distribution. The most common edge geometries of commercial tools are hone, chamfer, and chamfer with a hone. A novel method for designing tool edge geometry that combines experimental and simulation results is investigated in this paper. An uncoated carbide tool was used to orthogonally cut AISI 1045 and AISI 4140 steel. By observing how the tool geometry changed during the machining process with white light interferometry, a new tool wear geometry model could be proposed. Furthermore, temperature and stress distribution modeling were carried out with Finite Element Analysis (FEA) based on the newly designed tool geometry under various cutting parameters. A comparison of the machining results of the new and conventional tool geometries has confirmed that the newly designed tool is capable of achieving a lower wear rate, thereby extending the tool life.