Effects of random aspects of cutting tool wear on surface roughness and tool life

The effects of random aspects of cutting tool flank wear on surface roughness and on tool lifetime, when turning the AISI 1045 carbon steel, were studied in this investigation. It was found that standard deviations corresponding to tool flank wear and to the surface roughness increase exponentially with cutting time. Under cutting conditions that correspond to finishing operations, no significant differences were found between the calculated values of the capability indexCp at the steady-state region of the tool flank wear, using the best-fit method or the Box-Cox transformation, or by making the assumption that the surface roughness data are normally distributed. Hence, a method to establish cutting tool lifetime could be established that simultaneously respects the desired average of surface roughness and the required capability index.