The effects of corner radius and edge radius on tool flank wear

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The use of cutting tools with a honed edge radius to protect the cutting edge from chipping is ever increasing. The basic understanding of the fundamental cutting mechanics in the presence of an edge radius is increasing as well. The present state of knowledge leads one to question how edge-radiused tools behave under conditions that are more practical than straight-edged orthogonal cutting. Presented here is a study of the interaction of edge radius with corner radius, the latter of which is commonly seen in turning, boring, and face milling processes. Turning test data show that tool flank wear can be minimized for up-sharp tools by using a moderate corner radius. For tools with an edge radius, a wear-minimizing corner radius still exists but is higher than for up-sharp tools. Physical interpretations of these direct and interaction effects are presented.

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Journal of Manufacturing Processes