Comparative analyses and investigations of chamfered and honed-edge tool geometries on tool wear, chip morphology, residual stresses and end-burr formation

Muhammad Asad, Hassan Ijaz, Muhammad Azhar Ali Khan, Mushtaq Khan, Tarek Mabrouki, Muhammad Usman Rashid

Research output: Contribution to journalArticlepeer-review

5 Citations (Scopus)

Abstract

Cutting simulations for chamfered-edge and honed-edge tools for rough-to-semi finishing operations in machining an aerospace grade aluminum alloy AA2024 have been presented in this work. A finite element based approach has been developed to comprehend and investigate the relative effects of various cutting edge geometries on chip morphology, end-burr and residual stresses. Additionally, the role of chip-breaker geometry in segmentation and fragmentation has been thoroughly examined. Moreover, to estimate the expected wear in different sections of the tool, stress fields have been plotted. Furthermore, effects of chamfered-tool' macroscopic parameters: chamfer-length and chamfer-angle on various aspects of cutting process have been discussed. Presented coupled temperature-displacement numerical model has been validated for various results concerning chip morphology, cutting forces and segmentation frequency with previously performed experimental work. Finally, recommendations are made for proper selection of tool-geometry for better tool life, surface integrity and lesser burr formation in machining AA2024.

Original languageEnglish
Pages (from-to)196-209
Number of pages14
JournalJournal of Manufacturing Processes
Volume80
Early online date8 Jun 2022
DOIs
Publication statusPublished - Aug 2022
Externally publishedYes

Keywords

  • Chamfered-edge tool
  • Honed-edge tool
  • Tool wear
  • Machining numerical analysis
  • Residual stresses
  • End-burr

ASJC Scopus subject areas

  • Industrial and Manufacturing Engineering
  • Strategy and Management
  • Management Science and Operations Research

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