Effect of edge hone radius on plowing-induced plastic deformation in hard milling: analytical modeling and experimental validation

Microstructure alteration in the machined surface layer has a major impact on the functional performances of machined metal parts. Plastic deformation induced by high intensity of localized thermo-mechanical loads is more prominent in hard machining. Edge hone is recognized as a method to diminish tool wear, prevent chipping, and therefore guarantee the surface quality in hard machining. However, the plowing effect resulted from edge hone induces severe friction and deep plastic deformation. In this paper, a thermo-mechanically coupled prediction model was developed to estimate the depth of plastic deformation considering the plowing effect. The depth of plastic deformation induced by machining with different edge hone radii could be effectively measured with the proposed prediction model. Hard milling experiments were conducted on AISI H13 steel to verify the proposed model. A quantitative comparison indicates that there is a good agreement between the experimental results and the predicted results with the relative errors ranging from 4.14 to 14.28 %. This research provides useful guidance for edge hone radius selection and guaranteed surface integrity.