Turning of stainless steel with worn tools having chamfered main cutting edges

A force model is proposed in this study for a single-point tool with a chamfered main cutting edge incorporating a wear factor. The variations of shear plane areas occurring in the tool-worn situation are also used. Cutting experiments are conducted on stainless steel bars and the experimental data correlated closely with the theoretical values. A preliminary discussion is also made of the design of special tool holders and their geometrical configurations. The tool holders were milled using medium carbon-steel bars and these holders with the mounting tips were ground to fit various specifications.     

Prediction of the cutting temperatures of stainless steel with chamfered main cutting edge tools

The main purpose of this report is to predict the temperature of carbide tip's surface and study the cutting forces of turning stainless steel with sharp chamfered main cutting tools. The friction forces and frictional heat generated on elementary cutting tools are calculated by using the measured cutting forces and the oblique cutting analysis. The heat partition factors between the tip and chip are solved by using the inverse heat transfer analysis, which utilizes temperature on the carbide tip's surface measured by infrared as the input. The temperature of the carbide tip's surface is solved by finite element analysis (FEA) and compared with those obtained from experimental measurements. A good agreement demonstrates the accuracy of the proposed model.     

A force model for nose radius worn tools with a chamfered main cutting edge

The three-dimensional cutting forces for nose radius tools with a chamfered main cutting edge incorporated with a tool-worn factor are presented in this paper. The variations in shear plane areas occurring in the tool-worn situation are used. The results obtained from the proposed model shows good agreement with the experimental data on both chip formation as well as cutting forces. In the experimental work the throwaway tips are locked onto the pocket of the tool holder. The holders for special tools are designed first. Next, the tool holders are manufactured by using medium carbon-steel bars and the mounting tips are designed based on various specifications. Finally, the nose radius tips mounting in the tool holder are ground to a wear depth, and the worn tool dimensions are measured by using a profile projector. The shear area and the friction area are calculated accordingly. Then the three-dimensional cutting forces will be obtained from those data.     

A study of high efficiency face milling tools

A new predictive force model for a single-tooth face milling cutter with a chamfered main cutting edge has been derived. Machining tests has been conducted for fly cutting with a chamfered main cutting edge tools on plane surfaces. An S45C medium carbon plate has been used as the workpiece matrial. Force data from these tests were used to estimate the empirical constants of the mechanical model and to verify its prediction capabilities. The results show a good agreement between the predicted and measured forces.Since tool manufacturers does not provide tools with selected combinations of chamfered main cutting edge, radial angle, axial angle and inclination angles, tool holders manufactured in-house were used in the tests. The tips were prepared to the required geometry using a tool grinder.