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JOURNALOFMATERIALSPROCESSINGTECHNOLOGY1702005115120MACHININGWITHCHAMFEREDTOOLSIACHOUDHURY,NLSEE,MOHDZUKHAIRIDEPARTMENTOFENGINEERINGDESIGNANDMANUFACTURE,UNIVERSITYOFMALAYA,50603KUALALUMPUR,MALAYSIARECEIVED12OCTOBER2004ACCEPTED27APRIL2005ABSTRACTTHEAPPLICATIONOFCHAMFEREDTOOLSINMETALCUTTINGISYETVERYMUCHLIMITEDDESPITETHEIRBETTEREDGESTRENGTH,RELATIVELYLITTLERESEARCHHAVEBEENDONESOFARTOUNDERSTANDTHEEFFECTOFTOOLGEOMETRYONCUTTINGVARIABLESANDTHEMECHANICSOFCHIPFORMATIONTHEPRESENTSTUDYFOCUSESONTHEPERFORMANCEOFCHAMFEREDTOOLSDURINGCONTINUOUSANDINTERRUPTEDTURNINGOFMEDIUMCARBONLOWALLOYSTEELSEVERALCUTTINGTESTSWERECONDUCTEDINTURNINGONACONVENTIONALLATHEMACHINEWITHCEMENTEDCARBIDECHAMFEREDSOLIDTOOLSANDITSPERFORMANCEWITHRESPECTTOCUTTINGFORCE,TOOLLIFEANDCHIPFORMATIONHAVEBEENINVESTIGATEDTHETOOLSWEREGROUNDTODIFFERENTCHAMFERWIDTHSVARYINGFROM010TO040MMATACONSTANTCHAMFERANGLEOF45ANDTOAVARYINGMAINCUTTINGEDGECHAMFERANGLESRANGINGFROM15TO35ATACONSTANTCHAMFERWIDTHOF020MMFORTHEPURPOSEOFINTERRUPTEDTURNING,FOURAXIALSLOTSWEREMILLEDONTHECYLINDRICALWORKMATERIALITHASBEENOBSERVEDTHATBOTHINCONTINUOUSANDINTERRUPTEDTURNING,WITHTHEINCREASECHAMFERWIDTH,BOTHTHEMAINCUTTINGFORCEANDFEEDFORCESINCREASESANDTHEEFFECTONTHEFEEDFORCEISMORESIGNIFICANTWITHTHEINCREASEOFCHAMFERANGLE,CUTTINGFORCESINCREASEDBUTATTHEMAXIMUMCHAMFERANGLE,BOTHMAINCUTTINGFORCEANDFEEDFORCEWERELOWTHECHIPTHICKNESSWASOBSERVEDTODECREASEWITHINCREASINGCHAMFERWIDTHHOWEVERTHEEFFECTOFCHAMFERANGLEONTHECHIPTHICKNESSWASINSIGNIFICANTSHEARANGLEINCREASEDWITHTHEINCREASEOFBOTHWIDTHANDANGLEOFTHECHAMFER2005ELSEVIERBVALLRIGHTSRESERVEDKEYWORDSINTERRUPTEDTURNINGCHAMFEREDTOOLSTOOLWEARSURFACEROUGHNESS1CERTAINSURFMANCESURFTHESEOFWITHETRYANDUSEDCHAMFEREDFERED09240136/DOI101016/JJMATPROTEC200504110INTRODUCTIONINPRACTICE,THEMACHININGPROCESSISOPTIMIZEDBASEDONOUTPUTVARIABLES,SUCHASTOOLWEAR,CUTTINGFORCES,ACEFINISH,CHATTER,CUTTINGTEMPERATUREETCTHEPERFOROFACUTTINGTOOLISEVALUATEDINTERMSOFTOOLLIFE,ACEFINISH,CUTTINGFORCES,POWERANDMETALREMOVALRATEDEPENDONTHETOOLGEOMETRY,FEED,CUTTINGSPEED,DEPTHCUTANDWORKMATERIALANDTOOLMATERIALPROPERTIES1RESEARCHONMETALCUTTINGMAINLYFOCUSESONMACHININGSHARPEDGEINSERTS/TOOLSTHEINVESTIGATIONOFTOOLGEOMFOCUSESONCATEGORIESSUCHASITHETOOLEDGEGEOMETRYIITHETOOLRAKEGEOMETRYTOOLSWITHCHAMFEREDEDGEAREFORMACHININGHARDMATERIALSDUETOTHEIREDGESTRENGTHCUTTINGTOOLTRAPSTHEWORKMATERIALOVERTHECHAMEDGEANDTHEFORMEDDEADMETALACTSLIKEACUTTINGEDGE,CORRESPONDINGAUTHORTEL60379675384FAX60379675330EMAILADDRESSIMTIZUMEDUMYIACHOUDHURYWHICHWEARTINGANDTANGENTIALISPRIMARYNESECONDARYANGLESTRENGTHENINGBREAKAGEPOSITIEDGEINCREASESCUTTINGFORCESMAYVSEEFRONTMATTER2005ELSEVIERBVALLRIGHTSRESERVEDINCREASESTHETOOLEDGESTRENGTHANDREDUCESTHETOOLSOMERESEARCHERSHAVEFOUNDTHATTHECHAMFEREDCUTEDGEISALMOSTCOMPLETELYFILLEDBYADEADMETALZONETHECHAMFERHASMOREINFLUENCEONTHEFEEDFORCETHANTHEMAINCUTTINGFORCEFORCE2,3WHENACHAMFERINTRODUCEDTOTHETOOLEDGE,THECHAMFEREDEDGEACTSASTHERAKEOFTHETOOLWITHALIMITEDLENGTHANDATALARGEGATIVERAKEANGLETHEMAINRAKEOFTHETOOLBECOMESTHERAKEATAPOSITIVE,NEUTRALORSLIGHTLYNEGATIVERAKETHECHAMFERENHANCESTHEPERFORMANCEOFTHETOOLBYTHETOOLEDGEANDREDUCINGTHEPOSSIBILITYOFCUTTINGTOOLSWITHANEGATIVECHAMFEREDEDGEANDVERAKEFACETRAPSTHEWORKMATERIALOVERTHECHAMFEREDANDTHEDEADMETALFORMEDACTSLIKEACUTTINGEDGETHATTHESTRENGTHANDREDUCESTHETOOLWEARHOWEVER,WITHDEADMETALZONEONTHECHAMFEREDEDGEARETHATONTHETOOLAREINCREASEDANDTHEDIMENSIONALACCURACYBECOMPROMISEDASTHESIZEOFTHEDEADMETALZONEMAYARYDURINGCUTTING4116PROCESSINGBEENMARYCLUDEDONFERDECREASEDSHARP6ICSUSINGRESEARCHERSGEOMETRYTHEISCUTTINGITTHESURFPROCESSTHECUTTINGTHICKNESSDICTSTRAIN,DIFACUTTINGCHAMFERUNDERSTANDINGTHEINMAININTERRUPTEDOFCHIPONSOLIDWIDTHS2CONDUCTEDFERENTPIECEALONGICALLY212118TCHAMFERTFIRSTSECONDTOOLGEOMETRYINATOOLGRINDERTHEVARIOUSANGLESWEREMAINRAKEANGLE5,SIDECLEARANCEANGLE5,BACKCLEARANCEANGLE8,ANDMINORTOOLCUTTINGEDGEANGLE10TABLE1SHOWSTHEVALUESOFDIFFERENTCHAMFERANGLESANDWIDTHSTHECOMPOSITIONOFTHETOOLIS55WC,10CO,AND35TACTICWITHHARDNESSHRAEQUALTO90522WORKPIECETHEWORKPIECEUSEDWASASSABSTEEL760HV221WITHC045ANDMN070FORBOTHCONTINUOUSANDINTERRUPTEDTURNINGFORINTERRUPTEDTURNING,FOURAXIALSLOTSASSHOWNINFIG1WEREMILLEDIACHOUDHURYETAL/JOURNALOFMATERIALSTHEMECHANICSOFMACHININGWITHCHAMFEREDTOOLSHAVEANALYZEDBYZHANGETAL5THEYCONSIDEREDTHEPRI,DEADMETAL,ANDDEFORMATIONZONESEPARATELYANDCONTHATEXISTENCEOFDEADMETALZONEWASNOTDEPENDENTTHECUTTINGSPEED,TOOLMAINRAKEANGLEORTHECHAMANGLETHEYOBSERVEDTHATSHEARANGLEDUETOCHAMFERBYABOUT23COMPAREDTOTHATFORCUTTINGWITHEDGETOOLSUNDERTHESAMECUTTINGCONDITIONSFUHETALHAVEMODELEDTHREEDIMENSIONALGEOMETRYANDMECHANOFTOOLSWITHACHAMFERANDPREDICTEDCUTTINGFORCESSHEARLAWSGOVERNEDBYMINIMUMENERGYPRINCIPLEHAVEALSOINVESTIGATEDTHEEFFECTOFTOOLEDGEONTHECHIPREMOVALPROCESSPREVIOUSRESEARCHONFUNDAMENTALOFMECHANICSOFCUTTINGSUGGESTSTHATCHIPFORMEDBYASHEARINGPROCESSALONGASHEARPLANEAHEADOFEDGETOWARDAFREESURFACEOFTHEWORKMATERIAL7,8ISBELIEVEDTHATTHEEDGEORTHEPLOUGHINGFORCEINFLUENCESSURFACEINTEGRITYANDRESIDUALSTRESSESINTHEMACHINEDACERATHERTHANCONTRIBUTINGDIRECTLYTOTHECHIPREMOVALSINCETHEREISNODIRECTMEASUREMENTTECHNIQUEFORPLOUGHINGFORCE,ITISINDIRECTLYESTIMATEDFROMTHETOTALFORCEBYEXTRAPOLATINGTHEFORCESATVARIOUSUNCUTCHIPTOZEROTHICKNESS9THISHOWEVERMAYOVERPRETHEPLOUGHINGFORCESINSOMECASESWHENTHEVARIATIONOFSTRAINRATE,ANDTEMPERATUREARETAKENINTOACCOUNTATFERENTFEEDRATES10,11CHANGANDFU12,13PRESENTEDFORCEMODELFORSINGLEPOINTCHAMFEREDTOOLSTOPREDICTTHEFORCETHEYALSOSUGGESTEDTHATWITHMAINCUTTINGEDGETOOLSCOULDIMPROVECUTTINGEFFICIENCY14RELATIVELYLITTLERESEARCHHAVEBEENDONETOWARDBETTEROFTHEINFLUENCEOFCHAMFEREDEDGETOOLONOUTPUTVARIABLESINCONTINUOUSANDINTERRUPTEDTURNINGTHISSTUDY,TOOLSWITHVARIOUSCHAMFEREDWIDTHSONTHECUTTINGEDGEHAVEBEENUSEDBOTHINCONTINUOUSANDTURNINGTHEOBJECTIVESARETODETERMINETHEEFFECTCHAMFERWIDTHONTHECUTTINGFORCE,SURFACEROUGHNESS,THICKNESS,ANDTOOLLIFEEXPERIMENTSWERECONDUCTEDAMEDIUMCARBON,LOWALLOYSTEELASSAB760USINGCEMENTEDCARBIDECUTTINGTOOLSHAVINGVARIOUSCHAMFEREXPERIMENTALMETHODANDPROCEDUREINCONTINUOUSTURNING,ASERIESOFEXPERIMENTALRUNWEREONA140MMDIAMETERCYLINDRICALBARUNDERDIFCUTTINGCONDITIONSWHILEININTERRUPTEDTURNING,WORKDIAMETERWAS80MMWITHFOUR6MMWIDESLOTSMADETHELONGITUDINALDIRECTIONTHESOLIDTOOLSWERESPECIFGROUNDACCORDINGTOTHEREQUIREDGEOMETRYCUTTINGTOOLSANDTOOLGEOMETRYCUTTINGTOOLSOLIDCEMENTEDCARBIDETOOLSOFSQUARECROSSSECTIONMM8MMAND75MMLONGWEREGROUNDATTHEDESIRED23MACHINECOMPONENTCHANNELYWTOOLSPECIFICATIONSETECHNOLOGY1702005115120ABLE1DIMENSIONSOFTHETOOLOOLCHAMFERANGLECHAMFERWIDTHMMSETOFEXPERIMENT145010245014345020445028545040SETOFEXPERIMENT115020225020330020435020EXPERIMENTALCONDITIONSANDSETUPALLTHEEXPERIMENTSWERERUNDRYINACONVENTIONALLATHETHEENGINELATHEWASEQUIPPEDWITHATHREEKISTLERDYNAMOMETERINCONJUNCTIONWITHAMULTICHARGEAMPLIFIERFORCESIGNALSWERERECORDEDINAOKOGAWADL1540DIGITALOSCILLOSCOPESURFACEROUGHNESSASMEASUREDBYAPORTABLESURFACEROUGHNESSTESTERWHILEWEARWASMEASUREDINATOOLMAKERSMICROSCOPETHEOFTHEEQUIPMENTSANDINSTRUMENTSUSEDINTHEXPERIMENTAREASFOLLOWSIACHOLCHESTERMASTERVERSUS3250,75KWCONVENTIONALLATHEWITHMAXIMUMSPINDLESPEEDOF2500REV/MINANDFEEDRANGEOF003612MM/REVFIG1WORKPIECEWITHFOURAXIALSLOTSPROCESSINGFIGSPEEDIIII24WEREFEEDOFANDANDING,FORCEMEASUREMENTSSIDERED25SUREDFIGFIG4EFFECTOFCHAMFERWIDTHONTHEMAINCUTTINGFORCEATDIFFERENTCUTTINGSPEEDIACHOUDHURYETAL/JOURNALOFMATERIALS2EFFECTOFCHAMFERWIDTHONTHEMAINCUTTINGFORCEATDIFFERENTCUTTINGIIKISTLERPIEZOELECTRICDYNAMOMETERMODEL9257AWITHAMULTICHANNELKISTLERCHARGEAMPLIFIERANDAYOKOGAWADL1540DIGITALOSCILLOSCOPEAPORTABLEPERTHOMETERMAHRFORMEASURINGSURFACEROUGHNESSVATOOLMAKERSMICROSCOPEANDAHIGHMAGNIFICATIONMICROSCOPEOPITIHOT100SFORMEASURINGANDOBSERVINGTOOLWEARCUTTINGFORCETESTSFORCONTINUOUSANDINTERRUPTEDTURNING,CUTTINGCONDITIONSCUTTINGSPEEDV40,80,120,160,AND200M/MIN,RATEF008,010,012,016,AND020MM/REV,ANDDEPTHCUTD10MMFIVETOOLSWITHDIFFERENTCHAMFERWIDTHONEWITHNOCHAMFERWEREUSEDINCONTINUOUSTURNINGFORCESWERERECORDEDINTHECASEOFINTERRUPTEDTURNBOTHTHECHAMFERWIDTHANDTHEANGLEWEREVARIEDANDSIGNALSWERERECORDEDFOREACHEXPERIMENTALRUN,THREEWEREMADEANDAVERAGEVALUEHASBEENCONCHIPTHICKNESSRATIOANDSHEARANGLECHIPSWERECOLLECTEDATEACHCUTTINGCONDITIONANDMEABYADIALGAGECHIPTHICKNESSANDTHETOOLCHIP3EFFECTOFCHAMFERWIDTHONTHEFEEDFORCEATDIFFERENTCUTTINGSPEEDFIGCONTACTRATIOSCONDITIONS26INGCHAMFERCUTCHAMFERFIGSPEEDTECHNOLOGY17020051151201175EFFECTOFCHAMFERWIDTHONTHEFEEDFORCEATDIFFERENTCUTTINGSPEEDLENGTHWEREALSOMEASUREDANDTHECHIPTHICKNESSANDSHEARANGLESWERECALCULATEDFORDIFFERENTCUTTINGTOOLLIFETESTSTHETOOLLIFETESTSWERECONDUCTEDONLYININTERRUPTEDTURNWITHCHAMFEREDTOOLSOFDIFFERENTANGLESATACONSTANTWIDTHOF020MMTHESPEED,FEED,ANDDEPTHOFWERE120M/MIN,012MM/REV,AND1MM,RESPECTIVELYANGLESWERE15,20,30,AND356EFFECTOFCHAMFERANGLEONTHEMAINCUTTINGFORCEATDIFFERENTCUTTING118PROCESSINGTECHNOLOGY1702005115120FIG331311ANDINATWFORCEATCHAMFEREDATWTHEWIDTHOBSERVFIG10EFFECTOFCHAMFERWIDTHONCHIPTHICKNESSIACHOUDHURYETAL/JOURNALOFMATERIALS7EFFECTOFCHAMFERANGLEONTHEFEEDFORCEATDIFFERENTCUTTINGSPEEDRESULTSANDDISCUSSIONSCUTTINGFORCESCONTINUOUSTURNINGTHEEFFECTOFCHAMFERWIDTHONTHEMAINCUTTINGFORCEFEEDFORCEWERERECORDEDATVARIOUSSPEEDSANDPLOTTEDFIGS2AND3FEEDANDDEPTHOFCUTWEREKEPTCONSTANT020MM/REVAND10MM,RESPECTIVELYFROMTHEFIG2,ITASOBSERVEDTHATATCONSTANTCHAMFERWIDTH,MAINCUTTINGREMAINSALMOSTUNCHANGEDWITHTHEINCREASEOFSPEEDLOWERWIDTHS010AND014MM,CHAMFEREDANDNONTOOLSPRODUCEDALMOSTIDENTICALFORCESHOWEVER,THELARGERWIDTHS020MMANDABOVE,FORCEMAGNITUDEASHIGHERALTHOUGHITDIDNOTCHANGEMUCHWITHRESPECTTOINCREASEOFSPEEDWITHRESPECTTOTHEFEEDFORCE,LARGERTOOLSPRODUCEDHIGHERFORCESANDTHEMAGNITUDESWEREEDTOINCREASEWITHTHEINCREASEOFSPEEDTHEREASONFIG8EFFECTOFCHAMFERWIDTHONTHECUTTINGFORCECOMPONENTSFIG9EFFECTOFCHAMFERANGLEONTHECUTTINGFORCECOMPONENTSFOROFEDGECUTTINGFIG11EFFECTOFCHAMFERANGLEONCHIPTHICKNESSHIGHERFORCESATHIGHERWIDTHSMAYBEDUETOTHEFORMATIONADEADMETALZONE4,WHICHISTRAPPEDUNDERTHECHAMFERBUTTHISMAYPROTECTTHETOOLFROMWEARINGUNDERHEAVYCONDITIONSFIG12EFFECTOFCHAMFERANGLEONSHEARANGLEFIG13EFFECTOFCHAMFERWIDTHONSHEARANGLEIACHOUDHURYETAL/JOURNALOFMATERIALSPROCESSINGTECHNOLOGY1702005115120119FIG14CHIPFORMATIONACHAMFERANGLE20,F008MM/REVANDV40M/MIN,ANDF016MM/REV,V200M/MIN,DCHAMFERANGLE30,F010MM/REVANDVFCHAMFERANGLE35,F008MM/REVANDV80M/MIN,ALLATD10MMFIG15TOOLLIFEVALUESATDIFFERENTCHAMFERANGLES312014,DIFDTURNINGSPEEDCUTTINGONCHAMFERWFEEDOTHERWIDTHHASPRONOUNCEDFIG16TOOLWEAROBSERVEDAFTERSEVENMINUTESCUTTINGTIMEUNDERAHIGHMAGNIFICATIONBCHAMFERANGLE15,F008MM/REVANDV40M/MIN,CANGLE1580M/MIN,ECHAMFERANGLE15,F008MM/REVANDV200M/MIN,INTERRUPTEDTURNINGFIGS4AND5SHOWSTHEEFFECTOFCHAMFERWIDTH010,020MMONTHEMAINCUTTINGFORCEANDFEEDFORCEATFERENTSPEEDSFORFEEDF012MM/REVANDDEPTHOFCUT1MMHERETHETRENDISALSOSIMILARLIKEINCONTINUOUSALTHOUGHFEEDFORCEDIDNOTCHANGEMUCHWITHTHETHETOOLWITHOUTANYCHAMFERRESULTEDINTHELOWESTFORCEFIGS6AND7SHOWTHEEFFECTOFCHAMFERANGLETHECUTTINGANDFEEDFORCESATVARIOUSSPEEDSWHENTHEANGLEWAS35,THEMAGNITUDEOFMAINCUTTINGFORCEASLOWERTHATTHATATANGLEOF30WHILEINTHECASEOFFORCE,CHAMFERANGLE35PRODUCEDTHELOWESTTHANALLANGLETOOLSFIGS8AND9SHOWTHEEFFECTOFCHAMFERANDANGLEONTHEMAINCUTTINGFORCEANDFEEDFORCEITBEENOBSERVEDTHATTHEWIDTHANDANGLEEFFECTSAREMOREONTHEFEEDFORCETHANONTHEMAINCUTTINGFORCEMICROSCOPEATV120M/MIN/IN,F012MM/REV,ANDD10MM120PROCESSINGTHESEIN32THETHEWIDTHS,HASOFVNESSBYINCREASESSTANTVTHINNERSPEEDANGLEVIEDUCEDALLTHEANDCHAMFER33WIDTHAGEFCUTTINGTHEINGANDDECREASEDANDPHENOMENAANGLE7UNIFORM4TOFEREDIACHOUDHURYETAL/JOURNALOFMATERIALSOBSERVATIONSARECONSISTENTWITHTHERESEARCHREPORTEDTHELITERATURES2,3CHIPTHICKNESSANDSHEARANGLEFIGS10AND11SHOWTHEVARIATIONOFCHIPTHICKNESSWITHWIDTHANDANGLE,RESPECTIVELYWHILEFIGS12AND13SHOWVARIATIONOFSHEARANGLEATDIFFERENTCHAMFERANGLEANDRESPECTIVELYASTHEWIDTHOFCHAMFERINCREASES,THEREBEENADECREASEINCHIPTHICKNESSRESULTINGINTHEINCREASECHIPTHICKNESSRATIOTHISLEADSTOANINCREASEINCHIPELOCITYHOWEVERASTHECHAMFERANGLEINCREASES,CHIPTHICKREMAINSUNCHANGEDANDTHISSUPPORTSTHEPREVIOUSWORKOTHERRESEARCHERS5FROMFIGS12AND13,SHEARANGLEWITHTHEINCREASEOFCHAMFERWIDTHORANGLEATACONSPEEDHOWEVER,THEINCREASEISONLY25FORWIDTHARIATIONTHEINCREASINGSHEARANGLEMEANSCHIPBECOMESANDTHINNERANDCOMESOFFATAHIGHERSPEEDASTHEINCREASESFORACONSTANTCHAMFERWIDTHORANGLE,SHEARALSOINCREASESTHEOBSERVATIONDOESNOTSUPPORTTHEWOFRESEARCHREPORTEDINTHELITERATURE5CHIPSPROATDIFFERENTCHAMFERANGLESARESHOWNINFIG14ATANGLES,CHIPSPRODUCEDARESPIRALWHICHMAYATTRIBUTETOPRESENCEOFTHEDEADMETALZONETHATFILLSTHECHAMFERMAKESTHECUTTINGPROCESSALMOSTIDENTICALFORDIFFERENTANGLESTOOLLIFETHETOOLLIFETESTSWERECONDUCTEDONLYATONECHAMFER020MMWITHFOURDIFFERENTCHAMFERANGLESANDAVERFLANKWEARVALUESWERERECORDEDUNDERAMICROSCOPETOOLAILURETIMEWASCALCULATEDFROMTHEPLOTOFWEARAGAINSTTIMEFORDIFFERENTCHAMFERANGLESFIG15SHOWSLIFEOFTOOLSHAVINGDIFFERENTCHAMFERANGLESTOOLHAVTHELOWESTCHAMFERANGLEPRODUCEDTHEHIGHESTTOOLLIFEITISCLEARTHATASTHECHAMFERANGLEINCREASED,TOOLLIFEHOWEVER,NOTCHFORMATIONWASOBSERVEDON1520CHAMFERANGLETOOLSAFTER5MINOFCUTTINGCHIPPINGWASNOTATALLOBSERVEDINANYOFTHECHAMFERTOOLSFIG16SHOWSHIGHMAGNIFICATIONPICTUREAFTERMINOFCUTTINGTHEFLANKWEARPROGRESSIONSEEMSTOBECONCLUSIONSINTHISPAPER,EXPERIMENTALSTUDIESHAVEBEENCONDUCTEDWARDSBETTERUNDERSTANDINGOFTHEPERFORMANCEOFCHAMTOOLSEITHERINCONTINUOUSORINTERRUPTEDTURNINGASTHESPEEDINCREASES,MAINCUTTINGFORCEREMAINSALMOSTTHESAMEATACONSTANTCHAMFERWIDTHORANGLEHOWEVERWITHTHEINCREASEOFCHAMFERWIDTH,MAINCUTTINGFORCEINCREASEDATACONSTANTSPEED1011121314TECHNOLOGY1702005115120EFFECTOFWIDTHORANGLEISMOREPRONOUNCEDONTHEFEEDFORCETHANTHEMAINCUTTINGFORCETHELARGESTCHAMFERANGLETOOLRESULTEDINTHELOWESTFEEDFORCEINDICATINGTHEABSENCEOFANYDEADMETALZONEWHENTHECHAMFERWIDTHISRELATIVELYLOW014MM,THEREISNOSIGNIFICANTDIFFERENCEBETWEENACHAMFEREDANDANONCHAMFEREDTOOLWITHRESPECTTOTHECUTTINGFORCEMAGNITUDETHESHARPTOOLWIDTH0MMPRODUCEDTHESMALLESTFORCECHIPTHICKNESSDOESNOTCHANGEWITHCHAMFERANGLEHOWEVERWITHTHEINCREASEOFWIDTH,CHIPTHICKNESSDECREASESANDATHIGHCUTTINGSPEED,CHIPTHICKNESSWASLOWERTHEREHASBEENASTEADYINCREASEINSHEARANGLEEITHERWITHTHEINCREASEOFWIDTHORANGLETHESHEARANGLEHOWEVERINCREASEDONLYBY25WHENWIDTHWASINCREASEDTHEINCREASEINTHESHEARANGLEWASEVENMOREWHENTHECHAMFERANGLEINCREASEDALMOSTIDENTICALCHIPWEREPRODUCEDIRRESPECTIVEOFCHAMFERANGLESANDATALLCUTTINGCONDITIONSINDICATINGTHEPRESENCEOFDEADMETALZONEONTHEFACEOFTHECHAMFERWHENTHECHAMFERANGLEWASTHESMALLEST,TOOLLIFEWASMAXIMUMTHERAPIDFLANKWEARATTHEINCREASINGCHAMFERANGLEMA