Cutting edge preparation of PCBN inserts by means of grinding and its application in hard turning

• A strategy is applied to reduce deviations in micro geometries produced by grinding.
• The abrasive grain size is the input parameter, which most affects insert quality.
• Asymmetric rounded edges contribute to tool life increase in hard turning.
• Asymmetric rounded edges increase compressive residual stresses in hard turning.

Since grinding is used to finish flank faces, a cutting edge preparation by means of this same process offers the possibility of finishing an insert in one clamping. On the other hand, cutting edge preparation in the region of insert corner radius demands a new method as a result of machine kinematic limitations. This work presents an investigation of cutting edge preparation of PCBN inserts by grinding and the verification of their applicability in hard turning. Results showed that the used method to prepare edge micro geometries is adequate and asymmetric roundings can increase tool life and compressive residual stresses.