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Abstract
This paper describes the relationship between flank wear area and cutting forces for turning operations. A set of experiments were
performed on a CNC lathe without coolant. The CNMG120412N-UJ tool insert was used to cut low alloy steel (AISI 4340). Flank wear
surface area was measured by surface texture instrument (Form TalysurfTM series) using a software package. Cutting forces were measured by
a KistlerTM piezo-electric dynamometer. The experimental results show that there is an increase in the three directional components of the
cutting force with increase in flank wear area. Among the three cutting forces measured, the tangential force is the largest while the radial force
is the smallest. However, when the tool insert begins to fail, all the three cutting forces increase sharply, especially so for the axial and radial
cutting forces. The radial force was also found to be slightly larger than the axial force when tool begins to fail. This paper also presents
mathematical modeling for better understanding of the relationship between flank wear area and cutting forces. The mathematical models
were solved by Matlab.
# 2002 Elsevier Science B.V. All rights reserved.
Keywords: Cutting force; Flank wear surface area
1. Introduction
Tool wear is a complex phenomenon occurring in different ways. Generally, worn tools adversely affect surface
finish of the workpiece; therefore there is a need to develop
tool-monitoring systems. This would alert the operator to the
state of a tool and avoid undesirable consequences. The
quest to develop a continuous monitoring system of tool
wear in a metal cutting operation is of great significance and
importance in underpinning and achieving the desired goal.
Two methods that hold the most promise for tool wear
monitoring are cutting forces and acoustic emission. One
of the most promising techniques for tool wear detection and
breakage involves the measurement of cutting forces. In
turning operations, it is convenient to consider the forces as a
three-component system. These are the tangential component, the axial component and the radial component. The
components of the cutting forces in metal cutting operations
provide a wealth of information on the metal removal
process. Changes in these forces indicate changes in machining parameters, such as depth of cut, feed rate, cutting speed
and condition of tool. Thus the accuracy of machining
*
Corresponding author.
0924-0136/02/$ see front matter # 2002 Elsevier Science B.V. All rights reserved.
PII: S 0 9 2 4 - 0 1 3 6 ( 0 2 ) 0 0 4 5 3 - 3
S.K. Sikdar, M. Chen / Journal of Materials Processing Technology 128 (2002) 210215
211
2. Experimental procedures
The cutting experiments were carried out on a CNC lathe.
Machining was carried on AISI 4340 steel using coated
carbide tool (Table 1). The tool holder was PCLNR 2525
Table 1
Specification of work material and cutting tool
Work material (AISI 4340 steel)
Typical analysis (%)
Hardness (HB)
Tooling details
Holder type
Tool type
212
S.K. Sikdar, M. Chen / Journal of Materials Processing Technology 128 (2002) 210215
Fig. 2. Cutting force vs. flank wear surface area (v 125 m/min,
f 0:4 mm/rev).
S.K. Sikdar, M. Chen / Journal of Materials Processing Technology 128 (2002) 210215
213
Fig. 3. Cutting force vs. flank wear surface area (v 165 m/min,
f 0:3 mm/rev).
Fig. 4. Cutting force vs. flank wear surface area (v 170 m/min,
f 0:25 mm/rev).
Table 2
Cutting speed v 125 m/min and feed rate f 0:4 mm/reva
No. of
observations
Cutting
time (min)
Maximum flank
wear VBmax (mm)
Tangential cutting
force Ft (N)
Axial cutting
force Fa (N)
Radial cutting
force Fr (N)
1
2
3
4
5
6
15
20
25
30
35
40
0.306
0.424
0.55
0.699
0.859
1.08
0.588
0.773
0.902
1.27
1.64
1.91
1882
1980
2272
2391
2463
2596
1793
1874
1996
2051
2192
2481
1020
1170
1279
1320
1542
2533
(5.2)
(14.7)
(5.3)
(3.1)
(5.4)
(4.5)
(6.5)
(2.8)
(6.8)
(13.2)
(14.7)
(9.3)
(3.2)
(16.8)
(64.3)
Table 3
Cutting speed v 165 m/min and feed rate f 0:3 mm/reva
No. of
observations
Cutting
time (min)
Maximum flank
wear VBmax (mm)
Tangential cutting
force Ft (N)
Axial cutting
force Fa (N)
Radial cutting
force Fr (N)
1
2
3
4
5
6
4
8
12
16
20
24
0.332
0.401
0.412
0.493
0.538
0.839
0.637
0.767
0.79
0.943
1.03
1.59
1412
1494
1523
1569
1627
1769
1262
1297
1312
1328
1397
1623
858
913
949
981
1020
1721
(5.8)
(1.9)
(3)
(3.7)
(8.7)
(2.8)
(1.1)
(1.2)
(5.2)
(16.2)
(6.4)
(3.6)
(3.4)
(3.9)
(68.7)
Table 4
cutting speed v 170 m/min and feed rate f 0:25 mm/reva
No. of
observations (mm)
Cutting
time (min)
Maximum flank
wear VBmax
Tangential cutting
force Ft (N)
Axial cutting
force Fa (N)
Radial cutting
force Fr (N)
1
2
3
4
5
6
18
24
30
36
42
48
0.322
0.47
0.619
0.79
0.859
1.02
0.629
0.878
1.15
1.52
1.63
2.04
1369
1381
1482
1493
1566
1705
1238
1327
1381
1421
1470
1672
791
821
897
929
973
1695
(0.9)
(7.3)
(0.7)
(4.9)
(8.8)
(7.2)
(4.1)
(2.9)
(3.5)
(13.7)
(3.8)
(9.3)
(3.6)
(4.7)
(74)
214
S.K. Sikdar, M. Chen / Journal of Materials Processing Technology 128 (2002) 210215
4. Discussions
The most commonly used criterion for the evaluation of
tool life is the amount of wear that has taken place in the rake
or flank surfaces of the cutting tool. Of the regular types of
tool wear, only flank wear and the resulting recession of the
cutting edge directly affect the workpiece dimensions and
quality. Thus the single most significant type of wear that
draws constant attention is flank wear. Ways and means of
predicting or measuring it have been the pursuit of researchers for a long time [13]. Table 5 shows the tool life criterion
based on ISO [20]. In this research, we measured maximum
flank wear up to 1mm for all experiments. Coated carbide
inserts were used for all experiments. We did not use a
coolant because dry cutting is ecologically desirable and it
will be considered necessary for manufacturing enterprises
in future. The advantages of dry cutting include: non-pollution of the atmosphere, absence of residue on the swart,
which will be reflected in reduced disposal and cleaning
costs. Dry cutting also reduces thermal shock. Several
researchers have done work in this area. Ravindra et al.
[21] developed a mathematical model to describe weartime
and wearforce relationships for turning operation. Cutting
force components have been found to correlate well with
progressive wear and tool failure. The results show that the
ratio between force components is a better indicator of the
wear process, compared with the estimate obtained using
absolute values of the forces. Oraby and Hayhurst [22] also
developed a mathematical model to describe the weartime
and wearforce relationships for steady centre lathe turning
conditions. The results showed that tool chipping and fracture usually caused a sudden increase in the magnitudes of
both the feed force and radial force components. Barata and
Mesquita [23] investigated the relationship between the
wear of sintered T15 high-speed steel cutting tools and
the associated cutting forces. The equations for the cutting
forces are established taking into account the influence of
both crater wear and flank wear. Lee et al. [24] studied the
efficiency of the dynamic component of cutting force in
providing ample sign of imminent tool failure either by
fracture or chipping.
From the experimental results, we found that the radial
cutting force was slightly (3%) larger than the axial force
when the cutting tool begins to fail. Ft is the main force
Table 5
Tool life criterion based on ISO [20]
Tool life criterion
Application
Catastrophic failure
S.K. Sikdar, M. Chen / Journal of Materials Processing Technology 128 (2002) 210215
5. Conclusions
The study indicates a good correlation between cutting
forces and the three-dimensional flank wear surface area in
turning operations. All cutting forces increase with the
increase of the flank wear surface area. Increasing flank
wear area results in an increasing area of contact between the
tool tip and the workpiece. The greater the value of the flank
wear area, the higher the friction of the tool on the workpiece
and high heat generation will occur, this ultimately causes
the higher value of cutting force.
The rate of increase (the tangential force increases by 6%,
the axial force increases by 13% and the radial force
increases by 64%) of axial and radial cutting force is higher
than the tangential cutting force, when tool insert begins to
fail. The tool damage spreads over the whole contact area
thereby causing a rapid increase in both axial and radial
force. The radial force was also found to be slightly larger
than axial force when tool insert begins to fail.
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