Cutting edge microgeometries in metal cutting: a review

摘要

For decades, attentions have been paid to metal cutting processes, especially for the critical components in aerospace, marine, medical industries, etc. Scholars investigated the influence of cutting parameters, tool geometry, lubricant, pursuing a deeper understanding of process signatures, better tool performance, and more superior surface integrity. Edge microgeometry is proved to be an essential factor that significantly influences the tool-workpiece-chip contact, plastic deformation, and heat generation, which in turn affects the cutting phenomena. This paper aims to provide an insight and scientific overview of the role of edge microgeometries in metal cutting, with special attention on material flow state, cutting mechanics, tool performance, as well as the surface integrity. The characterization of edge microgeometries includes edge types (honed, chamfered, mixed), size parameters (edge radius, form-factor K, chamfer angle, chamfer length), and edge preparation techniques (grinding, drag finishing, brushing, micro-blasting, etc.). The researches on the influence of edge microgeometries on material flow state and cutting mechanics are reviewed, mainly focusing on analytical modeling and finite element method to explain how the edge microgeometries affect cutting processes. Then, the researches on the influence of edge microgeometries on tool performance and surface integrity are well organized to present the various findings in these topics. From the current perspective, many scholars have noticed the importance of edge microgeometries in metal cutting and have done numerous researches on this topic. Summary and future suggestions are given based on their state-of-the-art contributions in the last section.