EVALUATION OF TOOL WEAR AND TOOL LIFE OF ADHESIVELY MOUNTED CUTTING TOOLS IN TURNING OPERATIONS

Abstract

Turning operations are influenced by tool wear and tool life, as well as manufacturing quality, productivity, dimensions and costs. Usually, in conventional cutting tools, mounting occurs in mechanical clamping systems which can generate local stresses, vibrations, assembly complexity and limitation of positioning the tool. Another alternative process is adhesive-based tool mounting where the cutting insert or tool is joined with the tool holder with a high-strength structural adhesive. The present work aims to investigate the wear behavior and useful tool life of the adhesive jointed cutting tools in turning along with an assessment of cutting data. The tool arrangement bonded is assessed under various cutting speeds, feed rates and depths of cut. Progressive flank wear, edge deterioration, and progressive changes at the cutting-edge as a function of machining is used to evaluate tool wear. The useful tool life is defined considering the allowable state of wear and satisfactory cutting ability for the specified tool life. The influence of machining parameters on wear progression and mechanical stability of the adhesive joint is also studied. The outcome will give an enhanced understanding of the feasibility of using a tool mounting with adhesives in conventional turning applications and machining conditions that can lead to controlled wear, stable operation and enhanced tool utilisation during these processes.