Full Content is available to subscribers

Subscribe/Learn More  >

Experimental Investigation and Mechanistic Modeling of the Effects of Tool Edge Hone Effects in Turning Operations

[+] Author Affiliations
Santosh Ranganath, Albert B. Campbell

Delphi Research Laboratories

Jihong Hwang

Higgins Grinding Technology Center

Paper No. IMECE2005-82893, pp. 833-842; 10 pages
  • ASME 2005 International Mechanical Engineering Congress and Exposition
  • Manufacturing Engineering and Materials Handling, Parts A and B
  • Orlando, Florida, USA, November 5 – 11, 2005
  • Conference Sponsors: Manufacturing Engineering Division and Materials Handling Division
  • ISBN: 0-7918-4223-1 | eISBN: 0-7918-3769-6
  • Copyright © 2005 by ASME


Cutting force predictions from machining process models are generally accurate to within 20% for a specific tool and work material combination over a wide range of cutting conditions when calibrations are accurately performed. The calibration implicitly assumes that the tool used in the cut has a sharp cutting edge (zero radius) or identical (and maybe unknown) cutting edge radius. Significantly higher errors (more than 20%) in force calculations are seen when the same calibration data is used for predictions across a wide range of edge radii, also referred to as an edge hone. This paper describes the preliminary experimental work done to understand the impact of a honed cutting edge on the calibration of the force coefficients used by mechanistic models. Tube turning tests were performed on gray cast iron using tools of varying edge radii, and the cutting and thrust forces measured. Useful correlations between the edge radius and the machining force were observed although some of the results were confounded by variations in the temperature at the cutting edge. A new mechanistic calibration approach is applied to obtain the force coefficients from the measured forces that gives accurate results when the ratio of chip thickness to edge radius is used to calibrate the forces. This method has the advantage of being dependent only on the geometric size of the honed edge in relation to the thickness of the chip that is being removed. This allows the calibration to be performed with lesser experimental effort, while still being valid for predictions over a wide range of edge radii. Validation of this approach was performed using a range of edge hone sizes with peak force prediction errors less than 17%.

Copyright © 2005 by ASME



Interactive Graphics


Country-Specific Mortality and Growth Failure in Infancy and Yound Children and Association With Material Stature

Use interactive graphics and maps to view and sort country-specific infant and early dhildhood mortality and growth failure data and their association with maternal

Citing articles are presented as examples only. In non-demo SCM6 implementation, integration with CrossRef’s "Cited By" API will populate this tab (http://www.crossref.org/citedby.html).

Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In