JOURNALOFMATERIALSPROCESSINGTECHNOLOGY1702005115120MACHININGWITHCHAMFEREDTOOLSIACHOUDHURY,NLSEE,MOHDZUKHAIRIDEPARTMENTOFENGINEERINGDESIGNANDMANUFACTURE,UNIVERSITYOFMALAYA,50603KUALALUMPUR,MALAYSIARECEIVED12OCTOBER2004ACCEPTED27APRIL2005ABSTRACTTHEAPPLICATIONOFCHAMFEREDTOOLSINMETALCUTTINGISYETVERYMUCHLIMITEDDESPITETHEIRBETTEREDGESTRENGTH,RELATIVELYLITTLERESEARCHHAVEBEENDONESOFARTOUNDERSTANDTHEEFFECTOFTOOLGEOMETRYONCUTTINGVARIABLESANDTHEMECHANICSOFCHIPFORMATIONTHEPRESENTSTUDYFOCUSESONTHEPERFORMANCEOFCHAMFEREDTOOLSDURINGCONTINUOUSANDINTERRUPTEDTURNINGOFMEDIUMCARBONLOWALLOYSTEELSEVERALCUTTINGTESTSWERECONDUCTEDINTURNINGONACONVENTIONALLATHEMACHINEWITHCEMENTEDCARBIDECHAMFEREDSOLIDTOOLSANDITSPERFORMANCEWITHRESPECTTOCUTTINGFORCE,TOOLLIFEANDCHIPFORMATIONHAVEBEENINVESTIGATEDTHETOOLSWEREGROUNDTODIFFERENTCHAMFERWIDTHSVARYINGFROM010TO040MMATACONSTANTCHAMFERANGLEOF45ANDTOAVARYINGMAINCUTTINGEDGECHAMFERANGLESRANGINGFROM15TO35ATACONSTANTCHAMFERWIDTHOF020MMFORTHEPURPOSEOFINTERRUPTEDTURNING,FOURAXIALSLOTSWEREMILLEDONTHECYLINDRICALWORKMATERIALITHASBEENOBSERVEDTHATBOTHINCONTINUOUSANDINTERRUPTEDTURNING,WITHTHEINCREASECHAMFERWIDTH,BOTHTHEMAINCUTTINGFORCEANDFEEDFORCESINCREASESANDTHEEFFECTONTHEFEEDFORCEISMORESIGNIFICANTWITHTHEINCREASEOFCHAMFERANGLE,CUTTINGFORCESINCREASEDBUTATTHEMAXIMUMCHAMFERANGLE,BOTHMAINCUTTINGFORCEANDFEEDFORCEWERELOWTHECHIPTHICKNESSWASOBSERVEDTODECREASEWITHINCREASINGCHAMFERWIDTHHOWEVERTHEEFFECTOFCHAMFERANGLEONTHECHIPTHICKNESSWASINSIGNIFICANTSHEARANGLEINCREASEDWITHTHEINCREASEOFBOTHWIDTHANDANGLEOFTHECHAMFER2005ELSEVIERBVALLRIGHTSRESERVEDKEYWORDSINTERRUPTEDTURNINGCHAMFEREDTOOLSTOOLWEARSURFACEROUGHNESS1CERTAINSURFMANCESURFTHESEOFWITHETRYANDUSEDCHAMFEREDFERED09240136/DOI101016/JJMATPROTEC200504110INTRODUCTIONINPRACTICE,THEMACHININGPROCESSISOPTIMIZEDBASEDONOUTPUTVARIABLES,SUCHASTOOLWEAR,CUTTINGFORCES,ACEFINISH,CHATTER,CUTTINGTEMPERATUREETCTHEPERFOROFACUTTINGTOOLISEVALUATEDINTERMSOFTOOLLIFE,ACEFINISH,CUTTINGFORCES,POWERANDMETALREMOVALRATEDEPENDONTHETOOLGEOMETRY,FEED,CUTTINGSPEED,DEPTHCUTANDWORKMATERIALANDTOOLMATERIALPROPERTIES1RESEARCHONMETALCUTTINGMAINLYFOCUSESONMACHININGSHARPEDGEINSERTS/TOOLSTHEINVESTIGATIONOFTOOLGEOMFOCUSESONCATEGORIESSUCHASITHETOOLEDGEGEOMETRYIITHETOOLRAKEGEOMETRYTOOLSWITHCHAMFEREDEDGEAREFORMACHININGHARDMATERIALSDUETOTHEIREDGESTRENGTHCUTTINGTOOLTRAPSTHEWORKMATERIALOVERTHECHAMEDGEANDTHEFORMEDDEADMETALACTSLIKEACUTTINGEDGE,CORRESPONDINGAUTHORTEL60379675384FAX60379675330EMAILADDRESSIMTIZUMEDUMYIACHOUDHURYWHICHWEARTINGANDTANGENTIALISPRIMARYNESECONDARYANGLESTRENGTHENINGBREAKAGEPOSITIEDGEINCREASESCUTTINGFORCESMAYVSEEFRONTMATTER2005ELSEVIERBVALLRIGHTSRESERVEDINCREASESTHETOOLEDGESTRENGTHANDREDUCESTHETOOLSOMERESEARCHERSHAVEFOUNDTHATTHECHAMFEREDCUTEDGEISALMOSTCOMPLETELYFILLEDBYADEADMETALZONETHECHAMFERHASMOREINFLUENCEONTHEFEEDFORCETHANTHEMAINCUTTINGFORCEFORCE2,3WHENACHAMFERINTRODUCEDTOTHETOOLEDGE,THECHAMFEREDEDGEACTSASTHERAKEOFTHETOOLWITHALIMITEDLENGTHANDATALARGEGATIVERAKEANGLETHEMAINRAKEOFTHETOOLBECOMESTHERAKEATAPOSITIVE,NEUTRALORSLIGHTLYNEGATIVERAKETHECHAMFERENHANCESTHEPERFORMANCEOFTHETOOLBYTHETOOLEDGEANDREDUCINGTHEPOSSIBILITYOFCUTTINGTOOLSWITHANEGATIVECHAMFEREDEDGEANDVERAKEFACETRAPSTHEWORKMATERIALOVERTHECHAMFEREDANDTHEDEADMETALFORMEDACTSLIKEACUTTINGEDGETHATTHESTRENGTHANDREDUCESTHETOOLWEARHOWEVER,WITHDEADMETALZONEONTHECHAMFEREDEDGEARETHATONTHETOOLAREINCREASEDANDTHEDIMENSIONALACCURACYBECOMPROMISEDASTHESIZEOFTHEDEADMETALZONEMAYARYDURINGCUTTING4116PROCESSINGBEENMARYCLUDEDONFERDECREASEDSHARP6ICSUSINGRESEARCHERSGEOMETRYTHEISCUTTINGITTHESURFPROCESSTHECUTTINGTHICKNESSDICTSTRAIN,DIFACUTTINGCHAMFERUNDERSTANDINGTHEINMAININTERRUPTEDOFCHIPONSOLIDWIDTHS2CONDUCTEDFERENTPIECEALONGICALLY212118TCHAMFERTFIRSTSECONDTOOLGEOMETRYINATOOLGRINDERTHEVARIOUSANGLESWEREMAINRAKEANGLE5,SIDECLEARANCEANGLE5,BACKCLEARANCEANGLE8,ANDMINORTOOLCUTTINGEDGEANGLE10TABLE1SHOWSTHEVALUESOFDIFFERENTCHAMFERANGLESANDWIDTHSTHECOMPOSITIONOFTHETOOLIS55WC,10CO,AND35TACTICWITHHARDNESSHRAEQUALTO90522WORKPIECETHEWORKPIECEUSEDWASASSABSTEEL760HV221WITHC045ANDMN070FORBOTHCONTINUOUSANDINTERRUPTEDTURNINGFORINTERRUPTEDTURNING,FOURAXIALSLOTSASSHOWNINFIG1WEREMILLEDIACHOUDHURYETAL/JOURNALOFMATERIALSTHEMECHANICSOFMACHININGWITHCHAMFEREDTOOLSHAVEANALYZEDBYZHANGETAL5THEYCONSIDEREDTHEPRI,DEADMETAL,ANDDEFORMATIONZONESEPARATELYANDCONTHATEXISTENCEOFDEADMETALZONEWASNOTDEPENDENTTHECUTTINGSPEED,TOOLMAINRAKEANGLEORTHECHAMANGLETHEYOBSERVEDTHATSHEARANGLEDUETOCHAMFERBYABOUT23COMPAREDTOTHATFORCUTTINGWITHEDGETOOLSUNDERTHESAMECUTTINGCONDITIONSFUHETALHAVEMODELEDTHREEDIMENSIONALGEOMETRYANDMECHANOFTOOLSWITHACHAMFERANDPREDICTEDCUTTINGFORCESSHEARLAWSGOVERNEDBYMINIMUMENERGYPRINCIPLEHAVEALSOINVESTIGATEDTHEEFFECTOFTOOLEDGEONTHECHIPREMOVALPROCESSPREVIOUSRESEARCHONFUNDAMENTALOFMECHANICSOFCUTTINGSUGGESTSTHATCHIPFORMEDBYASHEARINGPROCESSALONGASHEARPLANEAHEADOFEDGETOWARDAFREESURFACEOFTHEWORKMATERIAL7,8ISBELIEVEDTHATTHEEDGEORTHEPLOUGHINGFORCEINFLUENCESSURFACEINTEGRITYANDRESIDUALSTRESSESINTHEMACHINEDACERATHERTHANCONTRIBUTINGDIRECTLYTOTHECHIPREMOVALSINCETHEREISNODIRECTMEASUREMENTTECHNIQUEFORPLOUGHINGFORC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LATD10MMFIG15TOOLLIFEVALUESATDIFFERENTCHAMFERANGLES312014,DIFDTURNINGSPEEDCUTTINGONCHAMFERWFEEDOTHERWIDTHHASPRONOUNCEDFIG16TOOLWEAROBSERVEDAFTERSEVENMINUTESCUTTINGTIMEUNDERAHIGHMAGNIFICATIONBCHAMFERANGLE15,F008MM/REVANDV40M/MIN,CANGLE1580M/MIN,ECHAMFERANGLE15,F008MM/REVANDV200M/MIN,INTERRUPTEDTURNINGFIGS4AND5SHOWSTHEEFFECTOFCHAMFERWIDTH010,020MMONTHEMAINCUTTINGFORCEANDFEEDFORCEATFERENTSPEEDSFORFEEDF012MM/REVANDDEPTHOFCUT1MMHERETHETRENDISALSOSIMILARLIKEINCONTINUOUSALTHOUGHFEEDFORCEDIDNOTCHANGEMUCHWITHTHETHETOOLWITHOUTANYCHAMFERRESULTEDINTHELOWESTFORCEFIGS6AND7SHOWTHEEFFECTOFCHAMFERANGLETHECUTTINGANDFEEDFORCESATVARIOUSSPEEDSWHENTHEANGLEWAS35,THEMAGNITUDEOFMAINCUTTINGFORCEASLOWERTHATTHATATANGLEOF30WHILEINTHECASEOFFORCE,CHAMFERANGLE35PRODUCEDTHELOWESTTHANALLANGLETOOLSFIGS8AND9SHOWTHEEFFECTOFCHAMFERANDANGLEONTHEMAINCUTTINGFORCEANDFEEDFORCEITBEENOBSERVEDTHATTHEWIDTHANDANGLEEFFECTSAREMOREONTHEFEEDFORCETHANONTHEMAINCUTTINGFORCEMICROSCOPEATV120M/MIN/IN,F012MM/REV,ANDD10MM120PROCESSINGTHESEIN32THETHEWIDTHS,HASOFVNESSBYINCREASESSTANTVTHINNERSPEEDANGLEVIEDUCEDALLTHEANDCHAMFER33WIDTHAGEFCUTTINGTHEINGANDDECREASEDANDPHENOMENAANGLE7UNIFORM4TOFEREDIACHOUDHURYETAL/JOURNALOFMATERIALSOBSERVATIONSARECONSISTENTWITHTHERESEARCHREPORTEDTHELITERATURES2,3CHIPTHICKNESSANDSHEARANGLEFIGS10AND11SHOWTHEVARIATIONOFCHIPTHICKNESSWITHWIDTHANDANGLE,RESPECTIVELYWHILEFIGS12AND13SHOWVARIATIONOFSHEARANGLEATDIFFERENTCHAMFERANGLEANDRESPECTIVELYASTHEWIDTHOFCHAMFERINCREASES,THEREBEENADECREASEINCHIPTHICKNESSRESULTINGINTHEINCREASECHIPTHICKNESSRATIOTHISLEADSTOANINCREASEINCHIPELOCITYHOWEVERASTHECHAMFERANGLEINCREASES,CHIPTHICKREMAINSUNCHANGEDANDTHISSUPPORTSTHEPREVIOUSWORKOTHERRESEARCHERS5FROMFIGS12AND13,SHEARANGLEWITHTHEINCREASEOFCHAMFERWIDTHORANGLEATACONSPEEDHOWEVER,THEINCREASEISONLY25FORWIDTHARIATIONTHEINCREASINGSHEARANGLEMEANSCHIPBECOMESANDTHINNERANDCOMESOFFATAHIGHERSPEEDASTHEINCREASESFORACONSTANTCHAMFERWIDTHORANGLE,SHEARALSOINCREASESTHEOBSERVATIONDOESNOTSUPPORTTHEWOFRESEARCHREPORTEDINTHELITERATURE5CHIPSPROATDIFFERENTCHAMFERANGLESARESHOWNINFIG14ATANGLES,CHIPSPRODUCEDARESPIRALWHICHMAYATTRIBUTETOPRESENCEOFTHEDEADMETALZONETHATFILLSTHECHAMFERMAKESTHECUTTINGPROCESSALMOSTIDENTICALFORDIFFERENTANGLESTOOLLIFETHETOOLLIFETESTSWERECONDUCTEDONLYATONECHAMFER020MMWITHFOURDIFFERENTCHAMFERANGLESANDAVERFLANKWEARVALUESWERERECORDEDUNDERAMICROSCOPETOOLAILURETIMEWASCALCULATEDFROMTHEPLOTOFWEARAGAINSTTIMEFORDIFFERENTCHAMFERANGLESFIG15SHOWSLIFEOFTOOLSHAVINGDIFFERENTCHAMFERANGLESTOOLHAVTHELOWESTCHAMFERANGLEPRODUCEDTHEHIGHESTTOOLLIFEITISCLEARTHATASTHECHAMFERANGLEINCREASED,TOOLLIFEHOWEVER,NOTCHFORMATIONWASOBSERVEDON1520CHAMFERANGLETOOLSAFTER5MINOFCUTTINGCHIPPINGWASNOTATALLOBSERVEDINANYOFTHECHAMFERTOOLSFIG16SHOWSHIGHMAGNIFICATIONPICTUREAFTERMINOFCUTTINGTHEFLANKWEARPROGRESSIONSEEMSTOBECONCLUSIONSINTHISPAPER,EXPERIMENTALSTUDIESHAVEBEENCONDUCTEDWARDSBETTERUNDERSTANDINGOFTHEPERFORMANCEOFCHAMTOOLSEITHERINCONTINUOUSORINTERRUPTEDTURNINGASTHESPEEDINCREASES,MAINCUTTINGFORCEREMAINSALMOSTTHESAMEATACONSTANTCHAMFERWIDTHORANGLEHOWEVERWITHTHEINCREASEOFCHAMFERWIDTH,MAINCUTTINGFORCEINCREASEDATACONSTANTSPEED1011121314TECHNOLOGY1702005115120EFFECTOFWIDTHORANGLEISMOREPRONOUNCEDONTHEFEEDFORCETHANTHEMAINCUTTINGFORCETHELARGESTCHAMFERANGLETOOLRESULTEDINTHELOWESTFEEDFORCEINDICATINGTHEABSENCEOFANYDEADMETALZONEWHENTHECHAMFERWIDTHISRELATIVELYLOW014MM,THEREISNOSIGNIFICANTDIFFERENCEBETWEENACHAMFEREDANDANONCHAMFEREDTOOLWITHRESPECTTOTHECUTTINGFORCEMAGNITUDETHESHARPTOOLWIDTH0MMPRODUCEDTHESMALLESTFORCECHIPTHICKNESSDOESNOTCHANGEWITHCHAMFERANGLEHOWEVERWITHTHEINCREASEOFWIDTH,CHIPTHICKNESSDECREASESANDATHIGHCUTTINGSPEED,CHIPTHICKNESSWASLOWERTHEREHASBEENASTEADYINCREASEINSHEARANGLEEITHERWITHTHEINCREASEOFWIDTHORANGLETHESHEARANGLEHOWEVERINCREASEDONLYBY25WHENWIDTHWASINCREASEDTHEINCREASEINTHESHEARANGLEWASEVENMOREWHENTHECHAMFERANGLEINCREASEDALMOSTIDENTICALCHIPWEREPRODUCEDIRRESPECTIVEOFCHAMFERANGLESANDATALLCUTTINGCONDITIONSINDICATINGTHEPRESENCEOFDEADMETALZONEONTHEFACEOFTHECHAMFERWHENTHECHAMFERANGLEWASTHESMALLEST,TOOLLIFEWASMAXIMUMTHERAPIDFLANKWEARATTHEINCREASINGCHAMFERANGLEMA