FLANK WEAR AND ITS IMPLICATIONS ON THE

TOOL DIMENSIONAL STABILITY ASPECTS OF

SINGLE POINT CUTTING TOOL GEOMETRY
Vaishnavi Dhayapule1

1
PG Student, Department of Production Engineering, Sri Venkateswara University

College ofEngineering,Tirupati-517502, (India)

1
CorrespondingAuthor: Vaishnavi Dhayapule [email protected]

ABSTRACT: The state of a cutting tool is a critical factor in any metal cutting process because dull or
damaged machine tool. Different wear theories are in use to assess the wear phenomenon in metal cutting.
Amongst them, diffusion and adhesion wear theories are predominantly considered in determining the
crater wear and flank wear phenomena. The work herein proposes a mathematical approach for
determining worn tool cutting forces of a single point cutting tool in an orthogonal cutting. To say explicitly,
in the present work, simple mathematical formulae in terms of rake angle, relief angle and wear land are
utilized in the analysis of a single point cutting tool forces. Estimating wear land and its impact on the
geometry of a single point cutting tool assumes significance in view of the fact that the surface irregularity
changes caused by tool wear and results to the change of the cutting forces and energy consumption are
used as a criterion for estimating the cutting tool life and quality of the work piece.

Keywords:Flank wear, Cutting Forces, Cutting Velocity, Specific Energy, Worn Tool, Wear Land
Curve

1. INTRODUCTION

Father of Machine Tool –Henry Maudslay.

Single point cutting tools are those having one sharp cutting edge attached to the shank. The cutting edge is
intended to perform cutting, produce chips by the consumption of energy and create a machined surface on
the work piece. Cutting process with the single point cutting tool can be done in two main ways; Orthogonal
Cutting (Rake angle =0), Oblique cutting. This article is relevant to know the exact implications of flank wear
on cutting tool and also the ways of numerical theories and calculations to know its effect on the tool. The
objective of this article is to declare mainly the primary and secondary objectives.
Primary objective is to determine the dimensional changes takes place when the invariable values of the wear
land of the desired material are considered and calculated. Secondary objective is to determine the cutting
forces at different conditions and theories and compare the results of the worn tool by waldrof theory. By
considering the sharp tool and the worn tool, specific energy consumed during the machiningof the work
piece by the cutting tool is also determined clearly.
2. METHODOLOGY
To undergo the process of the cutting forces calculations and its energy consumption determinations, some of
the theories and methods are considered which are listed below,

● Merchant Theory

● Lee-Shaffer Theory

● Taylor’s Equation

● Waldrof Model for worn tool

● Energy consumptions of cutting planes

2.1. Merchant Theory:

The relationship between shear angle , rake angle, friction angle , cutting force, thrust force, frictional force
are considered .

Formula For Merchant Theory:

π
2ø + β – α = 2

Fig.2.1 Merchant Circle Diagram

.
2.2. Lee Shaffer Theory:
Lee Shaffer theory Lee and Shaffer’s relationship between and is derived on the assumption that:
A. The material being cut behaves like an ideal plastic which does not strain harden.
B. The shear plane represents a direction of maximum shear stresses in the material cut.
Assuming the possible slip line field to represent the present condition

Formula For Lee Shaffer Theory:

π
Ø+β – α= 4

Fig.2.2 Lee-Shaffer Theory Diagram

2.3. Taylor’s Equation:

To find the cutting speed and time consumed by the tool for the machining of workpiece in one go.

Formula Of Taylor’s Equation:

𝑛
V𝑇 = 𝐶

❖ Cutting Velocity effects the tool life at larger extent.

Fig.2.3 Velocity Vs Tool life Diagram

2.4.Waldrof’s Equation:

Waldrof model is used in predicting the worn tool

cutting forces(Ftw ,Fcw )and utilized the theory of slip-line
field to predict the stresses at the tool tip. By using those
stresses for determining the stress distribution on tool flank wear.

𝑉𝐵
Ftw=𝑤 ∫ σ𝑤(𝑥)𝑑𝑥
0

𝑉𝐵
Fcw=w ∫ τ𝑤(𝑥)𝑑𝑥
0

Fig.2.4. Mechanism of tool and workpiece

Where,
Fcw=Cutting force in cutting direction due to tool flank wear
Ftw=Cutting force in thrust direction due to tool flank wear
Fcs=Sharp tool cutting force in cutting direction
Fts=Sharp tool cutting force in thrust direction
α = Tool rake angle
tu=Uncut Chip Thickness.

It is to noted that summation of the cutting forces of the sharp tool and cutting forces of the worn tool together
results the actual cutting force of the machine tool.

Energy Consumption on cutting planes:

 Specific cutting energy-
𝐹𝐶 𝑉
𝑆𝑃𝐶𝐸 = 𝑉×𝑏×𝑡
Specific Shear Energy-
𝐹𝑆𝑉𝑆
𝑆𝑃𝑆𝐸 = 𝑉×𝑏×𝑡

Specific Friction Energy-

𝐹 𝑉𝐶
𝑆𝑃𝐹𝐸 = 𝑉×𝑏×𝑡

Where;
Fc=Force exerted in cutting direction
V=Cutting Speed
b- Width of cut
t= Chip thickness
Vs=cutting speed due to shear
𝑉cos𝑐𝑜𝑠 α
Vs= cos𝑐𝑜𝑠 (∅−α)
Fs= Force exerted on the shear plane direction
𝑉𝐶
r= 𝑉
;

F=Friction Force
Vc= Chip velocity
Vc=𝑟×𝑉

3.PROBLEM STATEMENT:

In my present work, to find the forces of the cutting tool at different machining parameter conditions of rake
angle, cutting speed, width of cut, uncut chip thickness etc;
Some of the conditions/cases are followed in this attempt:
3.1.CASE(1):
For the cutting tool-cemented carbide
To find the change in dimensional size and the volume of the tool worn following formulae are applied,
𝑤tan𝑡𝑎𝑛 θ
h = 1−tan𝑡𝑎𝑛 αtan𝑡𝑎𝑛 θ
2
𝑏𝑤 tan𝑡𝑎𝑛 θ
W= 2(1−tan𝑡𝑎𝑛 αtan𝑡𝑎𝑛 θ)
2
𝑏𝑤 tan𝑡𝑎𝑛 θ
Orthogonal Cutting: W= 2
(α = 0)
𝑉𝐵
cot 𝑐𝑜𝑡 θ = 𝑁𝐵
Where,
h =change in dimensional size
w =wear land size
for cemented carbide(roughing) w =0.762mm
for cemented carbide(finishing) w=0.3175mm.
θ= Clearance angle at the worn edge
α = rake angle
b =width of cut
VB= Width of the wear land
NB= wear normal to width of wear land

3.1.1.Cemented carbide(Roughing):
b =2.5mm
θ =20, 40, 60, 100
α
= -50 , 00 , 50 , 200
1. At α =− 5
θ=2
𝑤tan𝑡𝑎𝑛 θ
h= 1−tan𝑡𝑎𝑛 αtan𝑡𝑎𝑛 θ

0.762×tan𝑡𝑎𝑛 2
h= 1−tan𝑡𝑎𝑛 −52

h =0.0265mm
2
𝑏𝑤 tan𝑡𝑎𝑛 θ
W= 2(1−tan𝑡𝑎𝑛 αtan𝑡𝑎𝑛 θ)
2
2.5×0.762 tan𝑡𝑎𝑛 2
W= 2(1−tan𝑡𝑎𝑛 2×tan𝑡𝑎𝑛 −5

W=0.025mm

2
𝑏𝑤 tan𝑡𝑎𝑛 θ
For orthogonal Cutting :W= 2
2
𝑏𝑤 tan𝑡𝑎𝑛 θ
At θ = 2 ===W= 2
2
2.5×0.762 tan𝑡𝑎𝑛 2
W= 2

W=0.0253mm

Cemented Carbide (Finishing):

b =2.5mm
w =0.3175mm
θ =20, 40, 60, 100
α
= -50 , 00 , 50 , 200

1. At α =− 5
θ=2
𝑤tan𝑡𝑎𝑛 θ
h= 1−tan𝑡𝑎𝑛 αtan𝑡𝑎𝑛 θ

0.3175×tan𝑡𝑎𝑛 2
h= 1−tan𝑡𝑎𝑛 −52

h =0.0110mm
 2
𝑏𝑤 tan𝑡𝑎𝑛 θ
W= 2(1−tan𝑡𝑎𝑛 αtan𝑡𝑎𝑛 θ)
2
2.5×0.3175 tan𝑡𝑎𝑛 2
W= 2(1−tan𝑡𝑎𝑛 2×tan𝑡𝑎𝑛 −5

W=0.0043mm

2
𝑏𝑤 tan𝑡𝑎𝑛 θ
For orthogonal Cutting:W= 2
2
𝑏𝑤 tan𝑡𝑎𝑛 θ
At θ = 2 W= 2
2
2.5×0.3175 tan𝑡𝑎𝑛 2
W= 2

W=0.0044mm

⮚ Ratio of the width of the wear land to its normal is defined by the following formulae by considerin g

the clearance angle between them.

𝑉𝐵
cot 𝑐𝑜𝑡 θ = 𝑁𝐵
At θ = 2
𝑉𝐵
cot 𝑐𝑜𝑡 θ = 𝑁𝐵
𝑉𝐵
𝑁𝐵
= cot 𝑐𝑜𝑡 2

𝑉𝐵
𝑁𝐵
= 28. 63𝑚𝑚
Case-2:
Cutting Time(t) V=30 mpm V= 60 mpm V= 80 mpm V=100 mpm
(VB) (VB) (VB) (VB)
Start 0 0 0 0
5 0.075 0.375 0.575 0.825
10 0.150 0.525 0.775 1.025
15 0.250 0.650 1.05 1.25
20 0.40 0.80 1.30 1.53
Table.2.1. Relation between the cutting velocity and time

Note:Log V and Log T values are obtained by considering the above mean value at its extreme point on each
wear land curve.

Values of the Log v and t are:

 Log v Log t

log 30 =1.477 log 20=1.301

log 60=1.778 log 6=0.7781
log 80=1.903 log 3= 0.4771
log 100=2 log2=0.3010
Table.2.2. Log V Vs Log T

❖ By finding the slope of the above tabulated values, n value is obtained which is used to find the tool

life of the cutting tool at different cutting speed and time.

3.3.Case-(3):
As per stated in the condition of the paper [2], the coefficient of friction(µ) is nearly equal to unity. Three cases
are considered as follows;

μ=1;
μ<1;
μ>1;
3.3.1.At μ=1,FC=900; Ft=900,b =2.5mm, t=0.25mm, tc=1.0mm, α=-5,0,5,20
To find the friction angle and compare the results at different conditions of rake angle by following the formula
below;

β= ( )𝐹𝑡
𝐹𝑐
+α
At μ=1,FC=900; Ft=900,b =2.5mm, t=0.25mm, tc=1.0mm, α= -50

β= ( )𝐹𝑡
𝐹𝑐
+α

β= ( ) + (− 5)
900
900
0
β = 40

Substuiting the Friction angle value in merchant theory to find the shear angle and comparer the relation among
the values at different α, β values
Merchant Theory:
2∅ + β − α = π/2
0
At β = 40
α= -50
π
2∅ + β − α = 2
0
2∅ + 40 − (− 5) = π/2

Substuiting the Friction angle value in lee and Shaffer theory to find the shear angle and compare the relation
among the values at different α, β values
Lee and Shaffer Theory:
∅ + β − α = π/4
0
At β = 40
α= -50
∅ + β − α = π/4

∅ + 40 − (− 5) = π/4

0
∅ =0

Like wise for the below conditions also we can find the friction angle and can be determined the shear angle by
merchant and Lee-Shaffer Theroy.
3.3.2. At μ<1,FC=900; Ft=450,b =2.5mm, t=0.25mm, tc=1.0mm, α=-5,0,5,20

3.3.3.At μ>1,FC=700; Ft=900,b =2.5mm, t=0.25mm, tc=1.0mm, α=-5,0,5,20

3.4.Case (4):

✔ By considering the tool material as Cemented car bide and reference work piece material for the

cutting like (mild steel, cast iron)

✔ Analysis is to be done on those materials at different condition and method when the tool condition

is sharp and worn out after some revolutions.

✔ To find the cutting forces of the worn tool, Waldorf’s model equation (refer chapter-3) is used.

✔ Energy consumed by the sharp tool and worn tool is also found at 3 planes (cutting, shear,

friction).
3.4.1.Combination -1:Tool: Cemented carbide
Workpiece : Cast Iron
Combination:
Cemented carbide-Tool Cast Iron-Workpiece
VB=0.25mm-0.3mm τ𝑠 = 190 𝑚𝑝𝑎
0 0 0 0
Feed=0.4mm/rev α = − 5 , 0 , 5 , 20
tc= 1.0mm b =2.5mm
t =0.25mm
Formulae used:
𝑉𝐶
⯍ r= 𝑉
=
𝑡
𝑡𝑐
;
 ⯍ ∅=
𝑟cos𝑐𝑜𝑠 α
1−𝑟sin𝑠𝑖𝑛 α
;

⯍ 𝑏𝑡
AS = sin𝑠𝑖𝑛 ∅

⯍ Fs=τ𝑠 × 𝐴𝑆

𝐹𝑠
⯍ cos 𝑐𝑜𝑠 (β − α + ∅) = 𝑅

𝐹𝑡
⯍ Sin(β − α) = 𝑅

𝐹𝐶
⯍ Cos(β − α) = 𝑅

At α= -50;b=2.5mm,t=0.25mm
𝑡 0.25
r=𝑡 = 1.0
= 0. 25𝑚𝑚;
𝑐

𝑟𝑐𝑜𝑠α
∅= 1−𝑟𝑠𝑖𝑛α
0.25×𝑐𝑜𝑠⁡(−5)
∅= 1−0.25×𝑠𝑖𝑛⁡(−5)
0
∅ = 13. 69
𝑏𝑡
As = sin𝑠𝑖𝑛 ∅
0.25×2.5
As= sin𝑠𝑖𝑛 13.69

As=2.64mm
τ𝑠 = 190𝑚𝑝𝑎
Fs= τ𝑠 × 𝐴𝑆

Fs=190×2. 64
Fs=501.6N
R=FS/ cos 𝑐𝑜𝑠 (β − α + ∅)
R=1131.69N
Ft= sin 𝑠𝑖𝑛 (β − α)×𝑅
Fts= 866.92N
FC=cos 𝑐𝑜𝑠 (β − α)×𝑅
Fcs=727.43N

3.4.2.Worn Tool:
Combination-1:
Cemented carbide-Tool material
Cast Iron -Workpiece material
VB,width of cut, flow stress in shear direction.
Formulae used in estimating the cutting forces of a worn tool are as follows;
𝑉𝐵
Fcw=w ∫ τ𝑤(𝑥)𝑑𝑥
0
 𝑉𝐵
Ftw=w ∫ σ𝑤(𝑥)𝑑𝑥
0

VB=0.25mm-0.3mm,b=w=2.5mm
As we all know from the chapter-3 that,τ𝑤 = 𝐾, where K is equal to the shear strength of the sharp tool (τ𝑠)
𝑉𝐵
Fcw=w ∫ τ𝑤(𝑥)𝑑𝑥
0

0.25
♦ At VB=0.25mm,K=190.97mpa====Fcw=2.5 ∫ 190. 97(𝑥)𝑑𝑥
0

=2.5×190. 47(0. 25 − 0)
Fcw=121.8125N
♦ At VB=0.28mm,K=190.97mpa====Fcw=136.43N
♦ At VB=0.3mm,K=190.97mpa==== Fcw=146.17N
π
As we all know from the chapter-3 that,σ𝑤 = 𝐾(1 + 2
) where K is equal to the shear strength of the sharp tool

(τ𝑠)

σ𝑤 = 𝐾 1 + ( π
2 )= 2.57K
σ𝑤 = 190. 97 1 + ( 22
14)
2
σ𝑤 = 501. 35𝑁/𝑚𝑚

𝑉𝐵
Ftw=w ∫ σ𝑤(𝑥)𝑑𝑥
0

0.25
2
♦ At VB=0.25mm,σ𝑤=501.35 𝑁/𝑚𝑚 ====Ftw=2.5 ∫ 501. 35(𝑥)𝑑𝑥
0

=2.5×501. 35(0. 25 − 0)
Ftw=313.34N
2
♦ At VB=0.28mm,σ𝑤=501.35 𝑁/𝑚𝑚 ====Ftw=350.945N
2
♦ At VB=0.3mm,σ𝑤=501.35 𝑁/𝑚𝑚 ==== Ftw=376.0125N

It should be noted that actual cutting forces in the cutting and thrust directions, Fc and Ft
respectively, are the summation of the forces due to wear and the sharp tool cutting forces
when tool flank wear is not present,
Fc= Fcw+ Fcs;
Ft=Ftw+ Fts;
From the above calculations,
3.4.3.Combination :
Cemented carbide and Cast iron
Sharp tool:
0
At α= -50, ∅ = 13. 69
Fcs=727.43N
Fts= 866.92N
Worn Tool:
Fcw=134.804N
Ftw=346.765N
Fc= Fcw+ Fcs;
Fc=134.804+727.43
Fc=862.234N
Ft = Ftw+ Fts;
Ft=346.765+866.92
Ft=1213.685N

3.4.5.Specific Energy Consumption in Primary and Secondary Shear Zones

To find the specific energy consumption at different planes, foremost we have to find the following
nomenclature which are used to find in the following energy consumption formulae of the planes
(Cutting,shear,friction).
By the force equations,
Fs=𝐹𝑐 cos 𝑐𝑜𝑠 ∅ − 𝐹𝑡 sin 𝑠𝑖𝑛 ∅

F =𝐹𝑐 sin 𝑠𝑖𝑛 α + 𝐹𝑡 cos 𝑐𝑜𝑠 α

Energy consumption equation:

𝐹𝐶 𝑉
𝑆𝑃𝐶𝐸 = 𝑉×𝑏×𝑡
𝐹𝑆𝑉𝑆
𝑆𝑃𝑆𝐸 = 𝑉×𝑏×𝑡
𝐹 𝑉𝐶
𝑆𝑃𝐹𝐸 = 𝑉×𝑏×𝑡

Combination:
Cemented carbide-tool material
Cast Iron- Workpiece material
At α= -50;b=2.5mm,t=0.25mm,∅ = 13. 69
Fc=862.234N
Ft=1213.685N
Fs=𝐹𝑐 cos 𝑐𝑜𝑠 ∅ − 𝐹𝑡 sin 𝑠𝑖𝑛 ∅

Fs=862.234×cos(13.69)− 1213. 685×𝑠𝑖𝑛⁡(13. 69)

Fs=550.497N
F =𝐹𝑐 sin 𝑠𝑖𝑛 α + 𝐹𝑡 cos 𝑐𝑜𝑠 α

F =862. 234 sin 𝑠𝑖𝑛 (− 5) + 1213. 685 cos 𝑐𝑜𝑠 (− 5)

F=1133.917N
Specific Cutting Energy(SPCE)=
𝐹𝐶 𝑉
𝑆𝑃𝐶𝐸 = 𝑉×𝑏×𝑡
 862.234
SPCE= 2.5×0.25
2
SPCE=1379.5741N/𝑚𝑚
Specific Shearing Energy(SPSE):
𝐹𝑆𝑉𝑆
𝑆𝑃𝑆𝐸 = 𝑉×𝑏×𝑡
𝑉cos𝑐𝑜𝑠 α 550.497×31.54
• At V=30mpm, Vs= cos𝑐𝑜𝑠 (∅−α) =31.54m/min===SPSE= 30×2.5×0.25

2
SPSE=926.15N/𝑚𝑚

Specific Friction Energy(SPFE):

𝐹 𝑉𝐶
𝑆𝑃𝐹𝐸 = 𝑉×𝑏×𝑡
1231.685×0.25
SPFE= 2.5×0.25

2
SPFE=485.474 N/𝑚𝑚
By Following the above process of calculation, another combination -Cemented Carbide, Cast Iron can be
determined.

4.RESULTS AND GRAPHS:

From the above attempt it is clear by the calculations that the cutting forces of the tool at different conditions is
done by considering the 4 cases and determined the forces, VB, volume of the tool worn ,merchant theory
analysis etc;
4.1.Case-1: Cemented Carbide(Roughing):

α and ∅ h(change in dimensional W(Volume of the tool W(At α=0,Volume of the

size) worn) tool worn)
α =− 5 0.0265mm 0.025mm 0.0253mm
θ=2
α=0 0.0532mm 0.0507mm 0.0507mm
θ=4
α=5 0.0808mm 0.0769mm 0.0762mm
θ=6
α=5 0.143mm 0.1367mm 0.1279mm
θ=6

Table 4.1.1. Cemented carbide (Roughing)

Cemented Carbide(Finishing):

α and ∅ h(change in dimensional size) W(Volume of the tool worn) W(At α=0,Volume of
the tool worn)
α =− 5 0.0110mm 0.0043mm 0.0044mm
θ=2
α=0 0.022mm 0.00811mm 0.0088mm
θ=4
α=5 0.0336mm 0.0133mm 0.01324mm
θ=6
 α = 20 0.0598mm 0.0237mm 0.0222mm
θ = 10
Table 4.1.2. Cemented carbide (Finishing)

Values of clearance angle in terms of VB/NB are tabulated below:

cotθ 𝑉𝐵
𝑁𝐵
θ=2 28.63mm
θ=4 14.30mm
θ=6 9.51mm
θ = 10 5.67mm
Table 4.1.3. cotθ Vs VB/NB

From the above tabulated values, as the clearance angle varies which increases results to the relation of VB/NB,
decreases.

4.2. Case :2 Wear Land Curve:

Log V Vs Log T
4.3.Case-3:

Below tabulated results are following the condition of 🡺 μ=1 (All the values are in Degrees)

Rake angle(α) Friction angle(β) Merchant Theory(∅) Lee and Shaffer

theory(∅)
-5 40 22.5 0
0 45 22.5 0
5 50 22.5 0
20 65 22.5 0
Table 4.3.1 μ=1
🡺 μ<1

Rake angle(α) Friction angle(β) Merchant Theory(∅) Lee and Shaffer

theory(∅)
-5 21.5 31.75 18.5
0 26.5 31.75 18.5
5 31.5 31.75 18.5
20 46.5 31.75 18.5
Table 4.3.2. μ<1
🡺 μ>1

Rake angle(α) Friction angle(β) Merchant Theory(∅) Lee and Shaffer

theory(∅)
-5 47.12 37.8 -7.15
0 52.12 37.8 -7.15
5 57.12 37.8 -7.15
20 72.12 37.8 -7.15
Table 4.3.3. μ>1

4.4.Case-4:

Below tabulated values are determined by calculated the cutting forces at varied rake angles and
stipulated shear angles.

Combination : Cemented carbide and Cast Iron(Sharp Tool)

Rake angle(α) Shear angle( 2

As (𝑚𝑚 ) Fs (N) R (N) Fts (N) Fcs (N)
∅)
α =− 5 13.69 2.64 501.6 1131.69 866.92 727.43
α =0 14.036 2.576 489.44 951.29 672.66 672.66
α=5 14.28 2.533 481.27 824.33 529.96 631.48
α =20 14.40 2.513 477.47 617.89 261.131 560.05
Table 4.4.1. Cemented carbide and Cast Iron(Sharp Tool)

Cemented carbide and Cast Iron (Worn Tool)

VB Fcw Ftw
0.25mm 121.8125N 313.34N
0.28mm 136.43N 350.945N
0.3mm 146.17N 376.0125N
Table 4.4.2. Cemented carbide and Cast Iron(Worn Tool)

Below tabulated values are actual forces of cutting tool at cutting, shear, friction plane and their
energy consumption during machining.

Rake Shear Fc(N) Ft(N) Fs(N) F(N) SPCE SPSE SPFE

2 2
angle(α) angle(∅) (N/mm ) (N/mm ) (N/mm2)
-5 13.69 862.234 1213.685 550.497 1133.917 1379.574 926.18 485.474
0 14.036 807.464 1019.425 536.1132 1019.425 1292.2336 884.166 407.77
5 14.28 766.284 876.725 526.353 940.174 1226.0544 850.044 376.06
20 14.40 694.854 607.896 521.846 808.889 1111.76 788.276 323.556
Table 4.4.3. Cemented carbide and Cast Iron(Actual cutting Tool )

Below Tabulated values are forces exerted by the worn tool and energy consumed by the worn tool
while machining

Rake Shear Fcw(N) Ftw(N) Fs(N) F(N) SPCE SPSE SPFE

angle(α) angle(∅) (N/mm2) (N/mm2) (N/mm2)
-5 13.69 134.80 346.765 48.902 333.69 215.68 82.2 133.476
0 14.036 134.80 346.765 46.65 346.765 215.68 78.47 138.706
5 14.28 134.80 346.765 45.10 357.19 215.68 75.87 142.876
20 14.40 134.80 346.765 44.32 371.856 215.68 74.56 148.78
Table 4.4.4. Cemented carbide and Cast Iron(Worn Tool) and its energy consumption
5. CONCLUSION:

In this work and attempt has been made to determine the dimensional stability of the cutting tool by
selecting the respective tool material and combination of the workpiece. An attempt has been done by
considering the invariable standard condition of many literatures and references of the articles.
In the present article, have cleared determined the cutting forces at different rake angle, shear angles.
In this it has been clearly stipulated the conditions and its suitable scenarios of calculations by the
help of the merchant and Lee – Shaffer Theory. By considering the cutting tool condition before
machining (Sharp tool) and after machining (worn tool) calculated the cutting forces and determined
the energy consumed by them.
By this attempt it is helpful to get the cutting tool of the required dimensions and methods to predict
the cutting tool depending upon the energy it consumes and cutting forces it exerts. Through the prior
note of the condition of Cutting tool selection, lead time decreases and the production rate increases.

6. REFERENCES:

● David W. Smithey , Shiv G.Kapoor , and Richard E.DeVor;University of Illunois at

Urbana-Champaign:“A NEW MECHANISTIC MODDEL FOR PREDICTING WORN
TOOL CUTTING FORCES”,
● E. Usui, T. Shirakashi, “Analytical Prediction of cutting tool wear” 100(1984),
● H. Zhao, G.C.Barber*, Q. Zou (2002) , “A study of flank wear in orthogonal cutting with
internal cooling”
● S.C. Lim, Y.B. Liu, S.H. Lee, K.H.W. Seah , “Mapping the wear of some cutting tool
materials”,(1993)
● Viktor P. Astakhov* , “The assessment of cutting tool wear” studied by selecting the tool life
criterion to determine the accuracy of the machining , its stability and reliability.
● Jie Gu* , Gary Barber , Simon Tung , Ren-Jyh Gu , “ Tool life and swear mechanism of
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