Influence of cutting edge radius on the wear resistance of PM-HSS milling inserts

In parallel, 2D finite element cutting simulations based on Lagrangian thermo-viscoplastic formulation are used to analyse the tool-stress distributions within the tool coating and substrate. The results obtained from this study provide a fundamental understanding of the cutting mechanics for the coated tool used and can assist in the optimisation of tool edge design. Particularly, the results obtained from the simulations have confirmed that there exists an optimum cutting edge radius that minimizes tool stresses, especially within the coating layer, which seems to be a key factor in the case of milling in dry high speed conditions.