Simulation-based design and production of graded cutting edges on cutting tools

• Applicants: Professor Dr.-Ing. Dirk Biermann; Professorin Dr.-Ing. Petra Wiederkehr
• Subject Area: Metal-Cutting and Abrasive Manufacturing Engineering
• Term: since 2017
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 374073886

The fundamental research project dealt with a modelling approach of material removal during cutting edge preparation by abrasive wet-jet cutting. In this context, the overall objective was to predict a favorable process control for the targeted adjustment of the cutting edge microshape on the basis of the simulation. The investigations focused on carbide cutting tools. By means of experimental investigations, the results could be validated for different process controls.Based on the results of the project, it is evident that there is agreement between simulation and experiment and that important control and disturbance variables could be identified.Based on the achieved results, however, further investigation focal points can be derived, the investigation of which represents an important component for further applications of the process and tools prepared in this way. Due to the changing cutting speed over the drilling tool diameter as well as the changing wedge angle, it is possible to adapt the cutting behaviour to the prevailing cutting speed by means of a specific variable cutting edge rounding, in the following called grading. Thus, a favorable chip formation can be achieved and the efficiency as well as the tool life can be increased. If, in addition, the graded cutting edge rounding is combined with a cutting edge tilt specifically adjusted to the application, the adapted preparation process offers a high potential to significantly increase the performance of drilling tools. In order to bring these very specific requirements into the cutting edge of a drilling tool, the simulation-supported design of a beam processing is beneficial. The aim of the presented project initiative is to extend the results obtained from the basic project by the simulative mapping of complex machining strategies by beam machining and to use these results for a precise design of cutting edge shapes on drilling tools. The resulting higher complexity of the process to be considered must be analyzed in greater depth with regard to various adjustment and disturbance variables and mapped with the help of geometric-physical substitute models. The design of the mentioned drilling tools supported by the simulation system will be tested in a field test in comparison to untreated tools regarding tool life and application behaviour.

• DFG Programme: Research Grants