A finite-element analysis of machining with the tool edge considered

This paper deals with numerical and experimental analyses of the effect of the tool edge on the cutting process. The tool forces and temperature in the steady-state orthogonal cutting process, taking tool edge radius into consideration, are analyzed using the finite-element method (FEM). The effects of depth of cut and tool edge radius are investigated. Also, orthogonal cutting experiments are performed for 0.2% carbon steel with tools having three different edge radii, the tool forces being measured. The experimental results are discussed in comparison with the results of the FEM analysis. From the study, it is confirmed that a major cause of the 'size effect' is the tool edge radius and it is noted that an increase in the tool edge radius causes a change in the temperature distribution in the tool, particularly in the position of maximum temperature.