Effect of tool nose profile tolerance on surface roughness in finish turning

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[1] Sung, A.N.
[2] Ratnam, M.M.
[3] Loh, W.P.
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Ratnam, M.M. | 1600年 / Springer London卷 / 76期
关键词：
Although the influence of nose geometry of a cutting tool insert on the surface roughness of the finished workpiece has been studied in detail; the effect of the tool nose profile tolerance in new cutting inserts on the surface roughness has not been investigated in the past. In this paper; we study the effect of tool nose profile tolerance in new inserts on the surface roughness using simulation and experimental methods. In the simulation study; a high-resolution optical metrology system was used to capture an image of the tool nose. A sub-pixel edge detection approach combining moment invariance operator with modified Sobel 2-D filter operator was used to extract the nose edge profile. The workpiece profile was then generated digitally using the extracted nose profile; and the effect of the nose profile deviation on the surface roughness was assessed. The maximum differences in the surface roughness parameters Rt; Ra; and Rq between the surfaces generated by the actual tool nose and the ideal (circular) tool nose images were found to be 40.3; 26.1; and; 24.5 %; respectively. The simulation study showed that the nose profile deviation alone can cause the surface roughness to vary as much as 40.3 % (Rt) although the same type of inserts are used. The simulation results for Rt and Rq were found to agree well with the experimental data with less than 10 % difference for 79 % of the tool edges. Our study shows that although the nose radius tolerance is within the 10 % allowed in the ISO3685 standard; the nose profile deviation has a significant influence on the surface roughness. © 2014; Springer-Verlag London;
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