FEM analysis of edge preparation for chamfered tools

The chamfer enhances the performance of the tool by strengthening the edge and reducing the possibility of tool wear and breakage. The strength of the chamfered tool can be investigated by analysis of process variables. This research investigates the effects of chamfer width and chamfer angle on process variables (force, stress, tool temperature and tool stress) in machining of a mild carbon low alloy steel by a cemented carbide tool using finite element method. The simulations show that the dead metal zone created under the tool acts as the effective cutting edge of the tool and increases the cutting forces. The predicted results show that the effect of chamfer width and angle is more pronounced on the thrust force than the cutting force. It also investigates the effect of chamfer on the effective shear angle and chip thickness, and comparison with available experimental results is presented. Tool temperatures are also predicted which suggests the presence of an optimum chamfer angle from the viewpoint of maximum tool temperature.