Experimental and numerical analysis of hard turning with multi-chamfered cutting edges

The application of customized edge geometries in hard turning prepared by the discretization of edge rounding in several chamfers is expected to contribute to the increase of tool life and induction of compressive residual stresses, confirmed by experimental observations. Additionally, this paper presents numerical simulations of hard turning using finite element analysis in order to provide a better understanding of the mechanical and thermal loads involved in cuffing, considering the variation of the number of chamfers used to discretize the edge. It is demonstrated that the higher number of chamfers, the higher the mechanical load on the edge, although the thermal load is not affected (as a result of the increase in contact area, which contributes to a better distribution of the thermal energy). Thus, in the investigated process, mechanical load is the main responsible phenomenon for alterations in tool life.