The experimental investigation on the effect of tool edge radius in orthogonal metal cutting

It is well known that the tool edge radius affects the cutting forces generated in metal cutting. The effects of tool edge radius on cutting forces and chip thickness in orthogonal cutting of five different materials were investigated. Material behavior during orthogonal cutting was also investigated.;Statistical analysis was performed to determine the effect of each input factor and the interactions among different factors. The contribution of each input factor to the variation of cutting forces and chip thickness was studied.;The characteristic variation of tool edge radius along a cutting edge of commercially available tool inserts was analyzed.