Design and Manufacturing for Uniform and Variable Microgeomery Cutting Tools with

Cutting tool preparation - Review

Mohamed Yassin1, C. Vankatish1

1
Department of Mechanical Design and Manufacturing Engineering, School of Mechanical,
Chemical and Materials Engineering, Adama Science and Technology University, Adama,
Ethiopia – 1888.

Abstract

For the last three decide an extensive research is done on the cutting tool geometry because every
manufacturing and industrial sector is diverted the attention to modified design of both uniform
micro-geometry(UMG) cutting tool and variable micro-geometry (VMG) cutting tool to increase
tool performance. Different micro geometry of the cutting edge helps to improve cutting tool
performance and enhance tool life span. In order to develop the required design different edge
preparation techniques are used such as abrasive blushing, blasting, wet abrasive jet machining,
magnet polishing, laser machining and other. Furthermore, the effect of tool-edge geometry
extended to cutting process parameters, as it affects cutting forces, stresses, temperatures, surface
integrity and deformation zone. In the present study, comprehensive review on the various
research on cutting tool geometry for both uniform and variable tool micro geometry and their
effect as well as the design. Also the common edge preparation technique covered.

Key word: micro-geometry, edge preparation, tool performance, surface integrity, tool life

Nomenclatures
VMG……………… Variable micro geometry
f …………………… feed
t …………………… depth of cut
UVD ……………… Uniform micro geometry
 1. INTRODUCTION

1.1. Brief introduction about Cutting tool geometry

In Manufacturing process, the cutting tip situation and trimming tip geometry are the most
decisive factor for machining operation. In the machining operation, the cutting process have an
impact on the amount of heat generated and the physical stress on the cutting edge consequently,
result in wear. Furthermore, the surface finish of worked part is also highly affected by the
cutting edge geometry [1]. In addition to this, both work piece properties and the performance of
the cutting tool is determined by micro geometry. So from this, we can see the crucial role of
cutting tool edge shape on the overall property of the work piece. Therefore, tool edge geometry
should be design in prudent way. Proper chip formation process is mainly achieved by careful
design of cutting geometry, this will result in reducing cutting forces and increasing tool life. In
manufacturing industry, it is known that sharp edge tools are not too much enough tool life, so its
demand was become decreasing in most of the machining process. In order to overcome this,
tool manufacturer, bring different types of tool edge preparations this are hone, chamfer,
bichamfer, hone with chamfer and waterfall hone [2]. Combine effect of tool material and cutting
edge preparation can decrease tool wear [7]. Cutting tool preparation mainly focus on the design
of uniform cutting edge geometry and sometimes variable cutting edge geometry. A uniform
cutting edge geometry along the insert corner maintain small workpiece chip depth to tip radius
proportion, consequently uncut chip thickness becomes very small. Unfortunately, shearing
dominated by ploughing with minimum cutting edge follow as high stress and increase heat
concentration, therefore tool will wear quickly. Whereas, variable edge micro-geometry along
the insert corner has the ability to minimize stress concentration and the developed heat, this help
to hard turning at high feed rate and cutting speed with less tool wear [16]. Ineffective cutting
outcomes in improved deflection in the unprocessed which implies enhancement of mechanical
and thermal stress at elevated temperature [17]. Cutting tool micro geometry have pressure on
tool vibration, tool life, and surface integrity (residual stress), So, to enhance machining
operation process variable micro geometry (VMG) cutting tools that is the cutting change
through the cutting edge line with reference to unique manufacturing parameter should be
manufactured. Even though VMG cutting tool have superior advantage than uniform one it has
own limitation on the growths, these are requirement of advanced technology for their
manufacturing and edge preparation processes following extensive machine setup, fixturing, and
programming [4].

This comprehensive paper, attempt to review on the various research on cutting tool geometry
for both uniform and variable tool micro geometry and their effect as well as the design. Also the
common edge preparation technique covered. Finally, the how different edge preparation
technique the tool performance will discussed.

1.2. Variable cutting edge microgeomery Design

The common tool geometry are macro geometry and micro geometry. Macro geometry aspect of
the tool is design by considering the machining application, stress distribution, tool wear
development, chip flow, and chip removal and others. However, micro geometry of cutting tool
edge encompass the shape and size of different tool class with respect to geometry and is
fabricated by edge preparation process. The most well-known cutting edge tool preparation
processes in manufacturing areas are Brushing, blasting, Wet abrasive jet machining, magnetic
polishing and others. The required micro geometry in edge preparation process form at some
exact point in the edge. According to above explanation the influence of Micro geometry of
cutting edge encompass nearly all aspect of the machining operation namely tool wear, surface
integrity, mechanics of tool and temperature distribution in the machining operation zone [4].
Even it can affect the surface residual stress situation of working parts [5]. The shape of tools
must be fitted their machining application with high precision and process reliability. The main
factor in designing the microgeomery is machining parameter, machining condition, tool wear,
raw material, and surface condition of machined part. To achieve uniform cutting edge micro
geometry edge honing of cutting tool is accomplished through the whole length [4]. In every
design of cutting tool edge, more attention is need to give on the material used for cutting tool
with respect to its strength, thermal stability, wear also the coating types. Cutting tool tip is a
crucial circumstance of tool life and their performance [1]. So through cutting edge preparation
the consistency will be boosted by reduced chipping and defined rounding along the cutting
edge. Choosing Variable cutting tool edge, give work piece quality and tool life that can enhance
the performance of process [8]. When Variable tool edge geometry design influences process
parameters such as the structure of deformation zones, variation of temperature and developed
stress on the tool face, and mechanics cutting tool. These influence will result in changes in chip
flow, residual stress, tool wear resistance, and machinability [12]. Residual stress is a decisively
determined by tool edge geometry that means the cutting tool parameter such as feed (f),
thickness of cut (t) as well as cutting speed have no significant effect as compared to tool edge
geometry [10]. Furthermore, the effect of tool-edge geometry extended to cutting process
parameters, as it affects cutting forces, stresses, temperatures, surface integrity and deformation
zone [11].

An overall cutting tool micro geometry

Surface
Residual finish Tool
stress wear

Chip
Effect of White/da
Form tool rk
geometry Layer

Cutting Heat
Force Micro- Generation
hardness
variation

Figure.1: An outcome of tool geometry on various input in in lathe operation (Dogra, M., et.al,
2011)

2. Cutting tool edge preparation

In Manufacturing industry many cutting edge in different sizes and shape can be produced by
means of Abrasive Wet machining, blasting, brushing, magnet- or drag-finishing or by laser
machining techniques [14]. Nowadays cutting edge preparation gain more attention and
widespread use because of its less cost and great influence on machining process. Plenty of
literature is reported on the cutting tip preparation method. So it need careful selection of suited
technique due to its influence on edge properties and tool performance. That means, cutting edge
preparation not only changes the geometry but also the properties of the cutting edge. Cutting
edge preparation techniques is become one of an essential pillar of development of modern
cutting tool [6]. For continuously increasing performance of machine tools and the global market
competition it is essential to develop new cutting tool technology. All in all, in tool cutting edge
preparation the ultimate goal is to strengthen the cutting tool edge line in order to improve tool
life span, to decrease edge chipping tendency then therefore to enhance final part surface finish.
[15].

There are multi class of cutting edge micro geometry preparation technique are there in
manufacturing process. Each and every technique of preparation has its own area of application
on its accuracy, production rate and the assumed form of the micro geometry

a. b.

Figure. 2: a. Micro geometry edge preparations for a triangular insert with nose radius (Arrazola,
P. and Ozel, T., 2008), b. Uniform vs. variable microgeometery edge design (Özel et al., 2008)

To increase material removal rate with nose radius insert by keeping constant uncut chip
thickness to edge radius ratio through the insert and the workpiece. Uniform edge design limit
the potential of high performance cutting because it does not provide a uniform workpiece chip
depth to tip radius proportion, through the insert corner sustain in all conditions.

2.1. Table.1: Cutting edge treatment techniques

Edge preparation Description Ref.

Method
1. abrasive -Various Geometrical structure of honed cutting edge will be [5 6,
brushing produced 7, 13]
- Extensively applied to remove material for setting different
cutting edge rounding sizes smoothen rough edge and surface
treatments finished part
- The brush will take the form of wheels, disk brushes, cup
brushes, and wire end brushes
- This method only focus on the preparation of cutting tip
- Applied brush have an influence on residual stress and
 topography of the prepared cutting edge
- By this technique using different filament form and process
parameter can produce a lot of edge corner ranging from a
few microns to tens of microns
-Brushing parameters are oscillation speed, cutting speed,
feed, time, setting angle
2. Magnetic -Very analogous to a magnetic stirrer commonly used in in [13,
polishing chemical experiment 18]
- Magnetic polishing process commonly applied for
deburring and polishing small metal parts.
- It was preferable for high speed steel tools and have some
unique advantages compared to other techniques
- Arrangement of the process is very easy because in some
degree it can be automated, to minimize time consumed for
the interaction between human and process,
- An equipment’s are less costly and doesn.t required much
power in operation.
- Complex geometry of component is prepared
-The method has following parameters are: scope of shot, raw
material, angular speed of magnet, and time taken.

Polishing
material type,
• shot size,
• magnet
rotation speed,
• polishing
time.
Polishing
material type,
• shot size,
• magnet
rotation speed,
• polishing
time.
Polishing
material type,
• shot size,
• magnet
rotation speed,
• polishing
3.
time.
Abrasive Wet jet - This technique use erosion mechanism.to removes material [6,18]
machining from the cutting tool edge.
- this method enhances the compressive stress within the
cutting edge surface and the subsurface of coated tools, in
order to increase toughness and reliability of the cutting tool.
- Has some advantage using water with abrasive suspension,
when adjust cutting edges compared to blasting processes.
-The existence of liquid in operation will negatively affect the
surface roughness and result poor surface finish.
- This machine assist with build-up of residual stress on the
face of the tool which prevent surface corrosion.
- Further priority of this method is water involved in the
process which help to eliminate thermal crack and damage of
the workpiece.
- The process is too complex due to various parameter is
there that required consideration which affect the outcomes
the tool preparation

• Abrasive
media
• Jet mass
concentration
• Jet pressure
• Nozzle outlet
diameter
• Jet
 distribution
intensity
• Jet expansion
angle
• Relative jet
inclination angle
• Jet nozzle
distance
• Jet feed speed
- Parameters include: Abrasive material, Jet stress, Jet
arrangement concentration, Relative jet slop angle, Jet nozzle
displacement and Jet feed velocity, Nozzle outlet size Jet
deflection,

4. Blasting - One of cutting edge preparation techniques and also [4,

(wet and dry) mechanical pre-treatment of the tool surface before coating 13,18]
process
- recommended for small size edge nose (radii) that range
from 10 to 60 micron.
- Dry micro blasting is aimed for modifying of coated
surfaces of solid carbide
- But wet micro blasting has in turn focus on the modification
of tool microgeometery and surface quality.
- Wet blasting process is well known advantageous technique
of edge preparation because it has a lot of parameter that can
be changed for this case it can be precisely controlled.
 -Micro- Blasting Parameters are: Direction, blasting rate,
Focusing, Pressure, viscosity, and Nozzle size

• Orientation
• Blasting speed
• Fluidity
• Focusing
• Pressure
5. Laser machining
• Nozzle dia
- Laser machining of the cutting edges is thermal method and [18]
used in option for the above all mechanical cutting edge
preparation.
- It’s cheaper techniques

-The outcome is varying with the types laser and process

parameter
-One of the special features of the laser beam in this process
is Gaussian arrangement of the beam’s spot size, so that there
is a transformation area between the surface that has been
adjusted by the laser beam and the unaffected area.
• Pulse frequency
• Number of ablation layers
• Scanning speed
• Scan overlap facto
-Parameters of the laser machining are following: Number of
ablation layers, Pulse frequency, Scanning rate, Scan
coincidence facto
 Tool Geometry Eff ect on performance
90 85
80
70
70
60
60 55
Tool performance in %

50
40
40
30
20
10
0
blasting Brushing Magnetic Laser Wet abrasive
Polishing Machining jet machining

Preparation Techiniques

100

Figure.3: Average cutting Performance achieved using variously pretreated cutting edge (
Denkena, B. and Biermann, D., 2014)

Cutting material

Coating
 C u ttin g e d g e m i
No. parameters
Tool of cutting edge

Macrogeometry Thermal load

Tool wear
Effect on process
Vibration

Cutting speed Mechanical load

Cutting
parameters
Cutting width

Feed speed

Cutting depth

Figure.4. Cross-process impact of cutting tip microgeomery on interactions of process

parameters in machining process ( Denkena, B. and Biermann, D., 2014).

3. Conclusions:
In this comprehensive review, the basic work carried out on impact of various shape and size of
cutting tool material on the overall machining process. Comparison between uniform and
variable cutting edge micro geometry design and their effect. According to literature survey
frame work, the following finding is point out and they presented as follow:
 With respect to Machining parameters and machining condition, determined tool wear,
raw material, and surface integrity are among the most important considerations for
cutting edge micro geometric design
 Briefly some common cutting tool edge preparation and the effect on the cutting tool
efficiency was discussed.
 Various parameter that will result change in cutting tool geometry such as Heat
Generation, chip form, Surface finish, residual stress tool and other.
 VMG tools are cutting tools of which the size and/or shape of the edge varies along the
cutting edge
 The main factor in designing the microgeomery is machining parameter, machining
condition, tool wear, raw material, and surface condition of machined part. To achieve
uniform cutting edge micro geometry edge honing of cutting tool is accomplished
through the whole length

4. Reference:
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2. Arrazola, P. and Ozel, T., 2008. Numerical modelling of 3D hard turning using arbitrary
Lagrangian Eulerian finite element method. International Journal of Machining and Machinability
of Materials, 4(1), p.14.
3. Dogra, M., Sharma, V. and Dureja, J., 2011. Effect of tool geometry variation on finish turning – A
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Variable Microgeometry Cutting Tools. Journal of Manufacturing Science and Engineering,
140(1).
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Abrasive Brushing. Key Engineering Materials, 438, pp.1-7.
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during orthogonal turning operations of AISI1045 with coated WC-Co inserts. CIRP Journal of
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