On prediction of tool life and tool deformation conditions in machining with restricted contact tools

This paper first reviews the recently developed semi-empirical method for predicting tool life in machining with restricted contact (RC) tools. The method uses Oxley’s machining theory to predict cutting forces, tool-chip contact length and cutting temperatures for the corresponding plane face tool i.e., tool having the same cutting edge geometry but no RC. These predicted parameters and a set of empirical relations are then used to calculate the cutting temperatures and tool life under RC conditions. In this paper additional experimental results are used to verify the above method and validate the predictions. An attempt is then made to use the above method to predict tool deformation under RC conditions. Finally, a comparison between experimental and predicted results and the modifications implemented to improve the predictive method are given.