Research On Edge Preparation And Flank Wear Modeling Of Milling Cutting Insert

For down milling process with a rotating cutting tool, the tool life ofthe cutting insert has direct influence on milling efficiency and fabricationcost. In this research, cemented carbide inserts treated with7different edgepreparations methods (dragging, honing, laser machining, abrasive flowmachining, magneto-abrasive machining, abrasive blasting and brushing)were investigated to see their respective impacts on tool life.Firstly, down milling trials were implemented on304L austeniticstainless steel. Through the observation and analysis of flank wear VB andVB max, adhesive wear and oxidation wear were confirmed as the twomajor mechanism of insert wear. Then the complete wear chart of all thecutting inserts was drawn to evaluate the tool life of7edge preparation.Results showed that the radius rβproduced by edge preparation was themajor factor causing the variation of tool life:. When rβwas in the range of35μm～60μm, tool life shortened as rβincreased; in the normal phase ofwear, the wear speed accelerated as rβ increased. Besides, the surfacemodification brought by edge preparation can also obviously affect tolllife.Secondly, Principal Component Analysis method was used to buildthe regression models for flank wear. A system of real-time cutting forcesmonitor system was adopted to collect cutting forces. Taking all the cuttingforces, cutting angles as well as the chip roughness information as thepredictive variables, VB max as response variable, Principal ComponentAnalysis was able to eliminate the multiple linear regressions among the variables and reserve the elements mostly correlated to VB max. In the end,7regression models were presented responding to7edge preparations.Compared with the original wear statistics, the accuracy rate of predictingVB is higher than86.6%.