Cutting edge microgeometry has gained special attention of late in the machining research community. Machine tool vibration, tool life, and workpiece surface integrity are all influenced by cutting edge size/shape. To optimize the machining process, variable microgeometry (VMG) cutting tools, in which the edge microgeometry varies along the edgeline with respect to specific variables (such as machining parameters or expected tool wear), are manufactured. Despite the advantages of VMG tools, a major hindrance in their development is the manufacturing complexity that demands high precision multi-axis edge preparation processes following extensive machine setup, fixturing, and programming. This paper details the proof of concept of a design criterion, which leads to the manufacturing of VMG cutting tools by only traditional edge preparation processes. The present method relies on the existing relationship between the edge radius subsequent to the edge preparation process and the tool wedge angle. The validity of the proposed method is first examined by a numerical simulation of the edge preparation. Carbide cutting tool inserts are then designed based on the proposed idea. Robust VMG generation subsequent to edge preparation by microblasting is demonstrated through microgeometric measurements. VMG chemical vapor deposition-coated carbide tools manufactured by the proposed approach are evaluated for turning hardened steel, and optimal designs are identified with respect to tool life and workpiece surface roughness. To address the design consideration, finite element (FE) modeling provides valuable insight into the machining process. FE modeled stress and temperature distribution clarify the experimental observations and reveal the design constraints.
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January 2018
Research-Article
Design for Manufacturing of Variable Microgeometry Cutting Tools
N. Z. Yussefian,
N. Z. Yussefian
Sandvik Coromant Research and Development,
Lerkrogsvägen 19,
Hägersten, Stockholm SE12680, Sweden
e-mail: nima.zarifyussefian@sandvik.com
Lerkrogsvägen 19,
Hägersten, Stockholm SE12680, Sweden
e-mail: nima.zarifyussefian@sandvik.com
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A. Hosseini,
A. Hosseini
Mem. ASME
Machining Research Laboratory (MRL),
Faculty of Engineering and Applied Science,
University of Ontario Institute of
Technology (UOIT),
Oshawa, ON L1H 7K4, Canada
e-mail: Sayyedali.hosseini@uoit.ca
Machining Research Laboratory (MRL),
Faculty of Engineering and Applied Science,
University of Ontario Institute of
Technology (UOIT),
Oshawa, ON L1H 7K4, Canada
e-mail: Sayyedali.hosseini@uoit.ca
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K. Hosseinkhani,
K. Hosseinkhani
Department of Mechanical Engineering,
McMaster University,
1280 Main Street West,
Hamilton, ON L8S 4L7, Canada
e-mail: hosseik@mcmaster.ca
McMaster University,
1280 Main Street West,
Hamilton, ON L8S 4L7, Canada
e-mail: hosseik@mcmaster.ca
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H. A. Kishawy
H. A. Kishawy
Fellow ASME
Machining Research Laboratory (MRL),
Faculty of Engineering and
Applied Science,
University of Ontario Institute of
Technology (UOIT),
Oshawa, ON L1H 7K4, Canada
e-mail: Hossam.kishawy@uoit.ca
Machining Research Laboratory (MRL),
Faculty of Engineering and
Applied Science,
University of Ontario Institute of
Technology (UOIT),
Oshawa, ON L1H 7K4, Canada
e-mail: Hossam.kishawy@uoit.ca
Search for other works by this author on:
N. Z. Yussefian
Sandvik Coromant Research and Development,
Lerkrogsvägen 19,
Hägersten, Stockholm SE12680, Sweden
e-mail: nima.zarifyussefian@sandvik.com
Lerkrogsvägen 19,
Hägersten, Stockholm SE12680, Sweden
e-mail: nima.zarifyussefian@sandvik.com
A. Hosseini
Mem. ASME
Machining Research Laboratory (MRL),
Faculty of Engineering and Applied Science,
University of Ontario Institute of
Technology (UOIT),
Oshawa, ON L1H 7K4, Canada
e-mail: Sayyedali.hosseini@uoit.ca
Machining Research Laboratory (MRL),
Faculty of Engineering and Applied Science,
University of Ontario Institute of
Technology (UOIT),
Oshawa, ON L1H 7K4, Canada
e-mail: Sayyedali.hosseini@uoit.ca
K. Hosseinkhani
Department of Mechanical Engineering,
McMaster University,
1280 Main Street West,
Hamilton, ON L8S 4L7, Canada
e-mail: hosseik@mcmaster.ca
McMaster University,
1280 Main Street West,
Hamilton, ON L8S 4L7, Canada
e-mail: hosseik@mcmaster.ca
H. A. Kishawy
Fellow ASME
Machining Research Laboratory (MRL),
Faculty of Engineering and
Applied Science,
University of Ontario Institute of
Technology (UOIT),
Oshawa, ON L1H 7K4, Canada
e-mail: Hossam.kishawy@uoit.ca
Machining Research Laboratory (MRL),
Faculty of Engineering and
Applied Science,
University of Ontario Institute of
Technology (UOIT),
Oshawa, ON L1H 7K4, Canada
e-mail: Hossam.kishawy@uoit.ca
1Corresponding author.
Manuscript received March 29, 2017; final manuscript received September 21, 2017; published online November 17, 2017. Assoc. Editor: Guillaume Fromentin.
J. Manuf. Sci. Eng. Jan 2018, 140(1): 011014 (7 pages)
Published Online: November 17, 2017
Article history
Received:
March 29, 2017
Revised:
September 21, 2017
Citation
Yussefian, N. Z., Hosseini, A., Hosseinkhani, K., and Kishawy, H. A. (November 17, 2017). "Design for Manufacturing of Variable Microgeometry Cutting Tools." ASME. J. Manuf. Sci. Eng. January 2018; 140(1): 011014. https://doi.org/10.1115/1.4038206
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