ModernArtofMilling-SandvikCoromant.pptVIP

Carefully applied sharp edges can bring benefits in special finishing applications. Wears quickly (exception PCD) * Negative chamfer on CBN inserts is needed to strengthen the edge. The chamfer consists of a width and an angle, and the corners could be sharp or honed. The cutting forces are distributed over a defined area of the edge. * * * * A typical edge on a CBN inserts consists of three variables: the chamfer angle, the chamfer width, and the edge radius. Each of these variables effects the process, the component, or the insert itself. The larger the angle, the more the forces are directed into the bulk of the insert which strengthens the edge. This results in a compressive force which is the strength of hard metals such as carbide and CBN. However, the larger angle will also increase cutting forces and could result in push off or vibration. A broader chamfer spreads the cutting forces over a bigger area. Higher feed gives higher cutting forces, why you need a broader chamfer to maintain tool life. The allowable feed rate is determined by the surface finish requirements of the component. The edge radius (ER) is the key in providing a consistent surface finish. A honed edge provides “pre-wear” which is both positive and negative. The hone will protect against micro chipping but it will also reduce tool life and could lead to vibration as well. * * Sharp edge - Reinforced edge Minimized cutting forces and heat - High cutting forces Better surface finish and sharp tolerances - Strong edge Continuous cutting - Interrupted cutting If a sharp edge suffers from the edge chippings, better reinforcement (ER, higher angle) may improve tool life. If surface or shape deteriorates with a reinforced edge, a sharper edge may be needed Note that the above are general guidelines. However, the pattern can become more complex, with balancing of different effects. (E.g. for a weak grade or insert shape, a large angle can become detrimental, as the total cutting forces may