Edge preparation methods for cutting tools: a review

doi:10.1007/s11465-023-0766-y

Front. Mech. Eng.

2023, Vol. 18

Issue (4) : 50 https://doi.org/10.1007/s11465-023-0766-y

REVIEW ARTICLE

Edge preparation methods for cutting tools: a review

Yu ZHOU^1,², Wei FANG^1,², Lanying SHAO^1,², Yanfei DAI^1,², Jiahuan WANG^1,², Xu WANG^1,², Julong YUAN^1,², Weigang GUO³, Binghai LYU^1,²(

)

¹. College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou 310023, China
². Key Laboratory of Special Purpose Equipment and Advanced Processing Technology (Ministry of Education and Zhejiang Province), Zhejiang University of Technology, Hangzhou 310023, China
³. Special Equipment Institute, Hangzhou Vocational & Technical College, Hangzhou 310018, China

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Abstract

Edge preparation can remove cutting edge defects, such as burrs, chippings, and grinding marks, generated in the grinding process and improve the cutting performance and service life of tools. Various edge preparation methods have been proposed for different tool matrix materials, geometries, and application requirements. This study presents a scientific and systematic review of the development of tool edge preparation technology and provides ideas for its future development. First, typical edge characterization methods, which associate the microgeometric characteristics of the cutting edge with cutting performance, are briefly introduced. Then, edge preparation methods for cutting tools, in which materials at the cutting edge area are removed to decrease defects and obtain a suitable microgeometry of the cutting edge for machining, are discussed. New edge preparation methods are explored on the basis of existing processing technologies, and the principles, advantages, and limitations of these methods are systematically summarized and analyzed. Edge preparation methods are classified into two categories: mechanical processing methods and nontraditional processing methods. These methods are compared from the aspects of edge consistency, surface quality, efficiency, processing difficulty, machining cost, and general availability. In this manner, a more intuitive understanding of the characteristics can be gained. Finally, the future development direction of tool edge preparation technology is prospected.

Keywords edge preparation method preparation principle cutting edge geometry edge characterization tool performance

Corresponding Author(s): Binghai LYU

Just Accepted Date: 28 August 2023 Issue Date: 28 December 2023

Cite this article:

Yu ZHOU,Wei FANG,Lanying SHAO, et al. Edge preparation methods for cutting tools: a review[J]. Front. Mech. Eng., 2023, 18(4): 50.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-023-0766-y
https://academic.hep.com.cn/fme/EN/Y2023/V18/I4/50

Fig.1 (a) Edge defects [3], reproduced with permission from Elsevier; (b) cutting edge preparation.

Fig.2 Tool life map of edge shape parameters [7], reproduced with permission from Elsevier.

Fig.3 Framework of this review.

Fig.4 Basic shapes of a cutting edge.

Fig.5 Characterization methods of chamfering edges.

Fig.6 Single-chamfer edge types: (a) chamfer edge, (b) negative chamfer edge, and (c) flat edge.

Fig.7 Characterization error caused by the single-edge radius characterization method.

Fig.8 Form-factor characterization method of the cutting edge.

Fig.9 Geometric characterization method of the cutting edge.

Fig.10 Edge characterization methods associated with the cutting process: (a) proposed by Rodríguez [4] and (b) proposed by Denkena et al. [23].

Fig.11 Iterative fitting characterization methods: (a) proposed by Wyen et al. [20,24] and (b) proposed by Yussefian and Koshy [25].

Fig.12 Mechanical processing methods for edge preparation [12,28]. Reproduced with permissions from Refs. [12,28] from Elsevier.

Fig.13 Cutting edge preparation by grinding [29]. Reproduced under the terms of the CC BY license.

Fig.14 Customized cutting edge preparation by grinding [31]: (a) machining principle and (b) micromorphology of the prepared edge. Reproduced with permission from Elsevier.

Fig.15 Cutting edge preparation by elastic bonded superabrasive grinding wheels [34]: (a) material removal mechanism and (b) micromorphology of the prepared edge. Reproduced with permission from Elsevier.

Fig.16 Brush equipment and wear process of brush fiber during cutting edge preparation [3], reproduced with permission from Elsevier.

Fig.17 Five-axis brushing process.

Fig.18 Cutting edge preparation using brushing tools with filament-integrated diamond grits [42]: (a) machining equipment and (b) micromorphology of the prepared edge. Reproduced under the terms of the CC BY NC ND license.

Fig.19 Drag finishing equipment for cutting edge preparation [52], reproduced under the terms of CC BY license.

Fig.20 Preparation of the cutting edge by ultrasonic vibration drag finishing.

Fig.21 Schematic of gas?solid two-phase flow abrasive machining.

Fig.22 Abrasive jet machining process [57], reproduced under the terms of CC BY license.

Fig.23 Cutting edge preparation by an industrial robot guided nozzle [61]: (a) machining principle and (b) micromorphology of the prepared edge. Reproduced under the terms of the CC BY NC ND license.

Fig.24 Preparation of the cutting edge by elastic abrasive blasting.

Fig.25 Preparation of the cemented carbide insert edge by microabrasive blasting [17]: (a) machining principle and (b) micromorphology of the prepared edge. Reproduced under the terms of CC BY license.

Fig.26 Preparation of the coated tool edge by rectangular nozzle abrasive water jet machining.

Fig.27 Schematic of the material removal mechanism in abrasive flow machining.

Fig.28 Preparation of the cutting edge by tool rotation abrasive flow.

Fig.29 Tool edge preparation by rotating abrasive flow polishing. The viscoelastic abrasive media (left part) is reprinted with permission from Ref. [80] from Elsevier.

Fig.30 Preparation of the cemented carbide insert edge by vibration machining.

Fig.31 Principle of shear thickening polishing (STP) [81], reproduced with permission from Elsevier.

Fig.32 Shear thickening polishing (STP) of a complex shape tool [72]: (a) processing mechanism and (b) micromorphology of the prepared edge. Reproduced with permission from Springer Nature.

Fig.33 Brush tool-assisted shear thickening polishing (STP) of a tool with a complex shape [73]: (a) processing mechanism and (b) micromorphology of the prepared edge. Reproduced with permission from Springer Nature.

Fig.34 Flexible polishing pad as a machining tool to prepare the cutting edge: (a) processing principle and (b) micromorphology of the prepared edge.

Fig.35 Cutting edge preparation with flexible diamond tools [86]: (a) processing principle and (b) micromorphology of the prepared edge. Reproduced under the terms of CC BY NC ND license.

Fig.36 Nontraditional processing methods for edge preparation [12], reproduced with permission from Elsevier.

Fig.37 Magnetic abrasive machining equipment [43], reproduced with permission from Elsevier.

Fig.38 Double-disk magnetic machining to prepare the cutting edge.

Fig.39 Magnetorheological preparation for cutting edge [94]: (a) processing mechanism and (b) edge topography. Reproduced under the terms of CC BY license.

Fig.40 Edge preparation by laser machining [43], reproduced with permission from Elsevier.

Fig.41 Cutting edge preparation by laser marking [98]: (a) processing equipment and (b) micromorphology of the prepared edge. Reproduced under the terms of CC BY license.

Fig.42 Principle of cutting edge preparation by laser ablation with processing gas [99]: (a) processing equipment and (b) machining principle. Reproduced with permission from Laser Institute of America.

Fig.43 Process of cutting edge preparation by electrolytic abrasion [101]: (a) machining principle and (b) micromorphology of the prepared edge. Reproduced under the terms of CC BY license.

Fig.44 Cutting edge preparation of cutting tools by using plasma discharges in electrolyte [102]: (a) machining principle and (b) micromorphology of the prepared edge. Reproduced with permission from Elsevier.

Fig.45 Cutting edge preparation by indentation cathode electrolysis.

Fig.46 Principle of electroerosion edge honing [105], reproduced with permission from Elsevier. EDM: electrical discharge machining.

Fig.47 Cutting edge preparation by sinking electrical discharge machining [104]: (a) machining principle and (b) micromorphology of the prepared edge. Reproduced with permission from Elsevier. HSS: high-speed steel.

Fig.48 Cutting edge preparation by foil counterface electrical discharge machining [105]: (a) machining principle and (b) micromorphology of the prepared edge. Reproduced with permission from Elsevier.

Fig.49 Shape generation of honed and chamfered edges in electrical discharge machining [106], reproduced with permission from Elsevier.

Fig.50 Preparation of the nanotwinned cubic boron nitride (nt-cBN) cutting edge by combining (a) mechanical lapping and (b) ion beam polishing [110], reproduced with permission from Elsevier.

Fig.51 Comparison of edge preparation methods [43]: (a) cutting edge radius and (b) cutting performance. Reproduced with permission from Elsevier. AB: abrasive blasting; AFM: abrasive flow machining; AMM: abrasive magnetic machine; AS: abrasive slurry; B: brushing; D: drag; LM: laser machining; U: unprepared.

Fig.52 Edge morphology of the micromilling tool processed by four methods [44], reproduced under the terms of CC BY license.

Tab.1 Comparison of mainstream cutting edge preparation methods

Abbreviations
AFM	Abrasive flow machining
AJM	Abrasive jet machining
AMM	Abrasive magnetic machine
AS	Abrasive slurry
B	Brushing
CBN	Cubic boron nitrification
CFRP	Carbon fiber-reinforced polymer
DF	Drag finishing
EDEM	Extended distinct element method
EDM	Electrical discharge machining
EM	Electrochemical machining
G	Grinding
LM	Laser machining
MAM	Magnetic abrasive machining
MPM	Mechanical processing method
nt-CBN	Nanotwinned cubic boron nitride
NPM	Nontraditional processing method
PCBN	Polycrystalline cubic boron nitride
R-AFP	Rotary abrasive flow polishing
STP	Shear thickening polishing
VM	Vibration machining
Variables
A_α	Plough area
B_f	Cutting edge width
D_α	Distance from the intersection of the flank face extension line and the horizontal line at the vertex of the cutting edge to the flank surface
D_γ	Distance from the intersection of the rake face extension line and the horizontal line at the vertex of the cutting edge to the rake surface
f_a	Degree of cutting edge preparation
h	Uncut chip thickness
h₀	Undeformed chip thickness during tool machining is denoted
K	Form factor
l_β	Length of the chamfer edge
n	Cutting edge vertex
p	Area to the left of the cutting edge
P_α	Transition point of the cutting edge on the flank face during cutting process
P_γ	Transition point of the cutting edge on the rake face during cutting process
q	Area to the right of the cutting edge
r	Cutting edge radius
r₀	Arc radius of the edge
r₁, r₂	Transition radii
r_a	Radius of curvature of the highest point of the cutting edge
r_β	Fitted cutting edge radius
Δr	Distance between the line connecting the highest point of the edge arc and the theoretical tip
Ra	Surface roughness
s	Edge separation point
S	Edge symmetry
S_a	Degree of asymmetry of the contour
S_f	Extension area of the cutting edge relative to the flank face
S_r	Extension area of the cutting edge relative to the rake face
S_γ	Distance between the ideal tool tip and the transition point of the rake face
S_α	Distance between the ideal tool tip and the transition point of the flank face
α	Flank angle
γ	Macro rake angle
γ_e	Effective rake angle
γ_β	Angel between the chamfer edge and the rake face
θ	Angle between the symmetry axis of the cutting edge curve the bisector of the ideal tool tip angle
φ	Area between the line connecting the ideal tip to the highest point of the edge
φ₀	Cutting edge inclination angle

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