Development of a semi-empirical model for the design of edge geometry in cutting tools applied in machining processes

• Grant number: 24/04833-1
• Support Opportunities: Regular Research Grants
• Start date: August 01, 2024
• End date: July 31, 2026
• Field of knowledge: Engineering - Mechanical Engineering - Manufacturing Processes
• Principal Investigator: Carlos Eiji Hirata Ventura
• Grantee: Carlos Eiji Hirata Ventura
• Host Institution: Centro de Ciências Exatas e de Tecnologia (CCET). Universidade Federal de São Carlos (UFSCAR). São Carlos , SP, Brazil
• Associated researchers: Armando Ítalo Sette Antonialli ; João Gustavo Pereira da Silva ; Pedro Alexandre Rodrigues Carvalho Rosa
• Associated scholarship(s): 24/21052-3 - Effect of rake angle and chip thickness on the behavior of specific cutting force in machining hardened steel with CBN inserts, BP.TT; 24/21048-6 - Effect of rake angle and chip thickness on the behavior of specific cutting force in machining hardened steel with mixed ceramic inserts, BP.TT; 24/14790-8 - Effect of rake angle and chip thickness on the behavior of specific cutting force in machining hardened steel with coated cemented tungsten carbide inserts, BP.TT; 24/14219-9 - Determination of critical regions in the workpiece-tool-chip contact in orthogonal cutting of hardened steel with different tool materials and edge geometries, BP.TT

Abstract

Considering the characteristics of cutting tools for machining processes, such as high hardness and low fracture toughness, adequate edge geometry is essential to withstand the mechanical loads resulting from the process. This geometry must be specific for different operating conditions and is usually designed based on trial-error methodologies and comparative experimental data. Within this context and in order to advance the state of the art in a concrete and well-founded way, this project proposes a new methodology for the design of cutting tool edge geometries. It involves a semi-empirical model for determining the specific cutting force as a function of the tool-workpiece contact region, which, combined with an analytical model for calculating the acting stresses, will serve the goal of defining the most appropriate edge geometry in view of the process conditions. This methodology will allow minimizing the stresses applied to the tool cutting edge, contributing to the geometric and dimensional accuracy of the machined component, as well as to the surface integrity and tool life. In addition, cutting inserts of different materials and prepared with distinct edge geometries will be applied in tool life tests and the critical wear growth regions will be defined and compared to the regions of highest stresses, allowing the technological validation of the model. (AU)