Investigation of metal machining with rounded edge tools

The usage of new machining techniques, such as high-precision machining and micro-machining, in which the uncut chip thickness is often on the same order of magnitude as the tool edge dimension, has been increased in modern machining process. And this means that, the cutting edge roundness has become an important part of the cutting tool geometry and it?s effects on metal machining must be studied much more comprehensively.In this research, a theoretical study, which investigates the effects of edge radius in metal machinning was made. First a detailed literature review was conducted and then the effects of the cutting edge radius on cutting forces, machined surface roughness, cutting tool wear and temperature around the cutting edge was investigated based on the studies made by different researchers who worked on this subject.In the last section, a metal cutting model which explicitly contains the effects of cutting edge radius in metal cutting was studied to assess its validity. By using the experimental data obtained from the metal cutting literature, cutting forces were calculated and the results were compared with the experimental force data. It was seen that aforementioned model is successful at low values of undeformed chip thickness whereas it begins to give erroneous results as the undeformed chip thickness increases.