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Design and Analysis of Variable Micro-Geometry Tooling for Machining Using 3-D Process Simulations

Emerging machining techniques such as hard turning, hard milling and micro-mechanical machining, set high standards for tooling. These techniques, where the uncut chip thickness and the tool edge dimension are in the same order of magnitude, require cutting edges, which can withstand high mechanical and thermal induced stresses during machining. Since it has been known that sharp tools are not suitable for these kinds of operations, tool manufacturers have introduced different types of tool edge preparations. A common approach is to provide uniform edge preparation. In this paper, uniform and variable edge micro-geometry design inserts are utilized and tested for 3-D turning process. In 3-D tool engagement with workpiece, the thickness of the chip varies from a maximum equal to the feed rate to a minimum on the tool’s corner radius. The ideal tool edge preparation should posses a variable configuration which has larger edge radius at the primary cutting edge than at the trailing cutting edge. Here the key parameter is the ratio of uncut chip thickness to edge radius. If a proper ratio is chosen, for given cutting conditions a variable cutting edge along the corner radius can be designed or “engineered”. In this study, 3-D finite element analysis based process simulations are utilized to predict forces and temperatures on various edge micro-geometry tools. Predicted forces are compared with experiments. The temperature distributions on the tool demonstrate the advantages of variable edge micro-geometry design.