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

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 R_a and R_t for a worn tool. The Brammertz effect simulation, though not in agreement with the data of Knuefermann (2003 Knuefermann , M.M.W. ( 2003 ) Machining surfaces of optical quality by hard turning, School of Applied Sciences, Cranfield University, Cranfield, Bedfordshire, UK . [Google Scholar]) corroborated the modification proposed therein.