Edge preparation methods for cutting tools: a review

Abstract

Edge preparation can remove cutting edge defects, such as burrs, chippings, and grinding marks, generated in the grinding process and improve the cutting performance and service life of tools. Various edge preparation methods have been proposed for different tool matrix materials, geometries, and application requirements. This study presents a scientific and systematic review of the development of tool edge preparation technology and provides ideas for its future development. First, typical edge characterization methods, which associate the microgeometric characteristics of the cutting edge with cutting performance, are briefly introduced. Then, edge preparation methods for cutting tools, in which materials at the cutting edge area are removed to decrease defects and obtain a suitable microgeometry of the cutting edge for machining, are discussed. New edge preparation methods are explored on the basis of existing processing technologies, and the principles, advantages, and limitations of these methods are systematically summarized and analyzed. Edge preparation methods are classified into two categories: mechanical processing methods and nontraditional processing methods. These methods are compared from the aspects of edge consistency, surface quality, efficiency, processing difficulty, machining cost, and general availability. In this manner, a more intuitive understanding of the characteristics can be gained. Finally, the future development direction of tool edge preparation technology is prospected.

Graphical abstract

Keywords

edge preparation method / preparation principle / cutting edge geometry / edge characterization / tool performance

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Nomenclature

Abbreviations
AFM	Abrasive flow machining
AJM	Abrasive jet machining
AMM	Abrasive magnetic machine
AS	Abrasive slurry
B	Brushing
CBN	Cubic boron nitrification
CFRP	Carbon fiber-reinforced polymer
DF	Drag finishing
EDEM	Extended distinct element method
EDM	Electrical discharge machining
EM	Electrochemical machining
G	Grinding
LM	Laser machining
MAM	Magnetic abrasive machining
MPM	Mechanical processing method
nt-CBN	Nanotwinned cubic boron nitride
NPM	Nontraditional processing method
PCBN	Polycrystalline cubic boron nitride
R-AFP	Rotary abrasive flow polishing
STP	Shear thickening polishing
VM	Vibration machining
Variables
Aα	Plough area
Bf	Cutting edge width
Dα	Distance from the intersection of the flank face extension line and the horizontal line at the vertex of the cutting edge to the flank surface
Dγ	Distance from the intersection of the rake face extension line and the horizontal line at the vertex of the cutting edge to the rake surface
fa	Degree of cutting edge preparation
h	Uncut chip thickness
h0	Undeformed chip thickness during tool machining is denoted
K	Form factor
lβ	Length of the chamfer edge
n	Cutting edge vertex
p	Area to the left of the cutting edge
Pα	Transition point of the cutting edge on the flank face during cutting process
Pγ	Transition point of the cutting edge on the rake face during cutting process
q	Area to the right of the cutting edge
r	Cutting edge radius
r0	Arc radius of the edge
r1, r2	Transition radii
ra	Radius of curvature of the highest point of the cutting edge
rβ	Fitted cutting edge radius
Δr	Distance between the line connecting the highest point of the edge arc and the theoretical tip
Ra	Surface roughness
s	Edge separation point
S	Edge symmetry
Sa	Degree of asymmetry of the contour
Sf	Extension area of the cutting edge relative to the flank face
Sr	Extension area of the cutting edge relative to the rake face
Sγ	Distance between the ideal tool tip and the transition point of the rake face
Sα	Distance between the ideal tool tip and the transition point of the flank face
α	Flank angle
γ	Macro rake angle
γe	Effective rake angle
γβ	Angel between the chamfer edge and the rake face
θ	Angle between the symmetry axis of the cutting edge curve the bisector of the ideal tool tip angle
φ	Area between the line connecting the ideal tip to the highest point of the edge
φ0	Cutting edge inclination angle

Acknowledgement

We would like to express our appreciation to the National Natural Science Foundation of China (Grant No. 52175441).

Conflict of Interest

The authors declare that they have no conflict of interest.

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