Experimental investigation of high-speed hard turning by PCBN tooling with strengthened edge

During high-speed hard turning, the cutting edge of the insert is directly responsible for cutting and bears high magnitudes of force and thermal load, etc. The geometric structure of the edge directly affects the cutting performance of the tool and the surface quality of the workpiece. In this study, the chip morphology, cutting force, and the surface topography have been compared and analyzed by PCBN cutting tool with the sine-strengthened edge and the negative chamfered arc edge through the method of experiment. It was found that the lamellar width of the chip produced by the sine-strengthened edge is smaller. Therefore, it has a smaller cutting deformation when compared to the chip with arc edge. Moreover, there are significant differences in shape of both its lateral burrs. The sine-strengthened edge can reduce the cutting force of the tool, and the ratio between radial and tangential force is smaller, resulting in significantly better cutting performance than the tool with arc edge. Compared to a negative chamfered arc edge tool, the machined surface produced by the sine-strengthen edge close to zero kurtosis and lower Sa value, and it can obtain a better machined surface quality.

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