Influence of cutting-edge radius by an edge-honing process on the cutting tool life and coating

The demand for enhancing tool performance has increased as the use of difficult-to-cut materials increases. The edge-honing process is one of the methods to enhance the tool performance by adjusting the radius of the cutting-edge. This study used a finite element analysis program to compare the cutting force, cutting temperature, and chip curl radius, assuming a cutting-edge radius of 5, 10, 15 and 20 µm. In addition, the cutting force, cutting temperature, surface roughness of the workpiece, and tool wear were confirmed through machining experiments. The experimental results indicated that the edge-honing process adversely affects the uncoated tool while positively affecting the coated tool by suppressing tool wear. Finite element analysis and machining experiments confirmed that the edge-honing process positively affects tool life and coating.