Effect of the Built-Up-Edge on Tool Wear in Machining of STAVAX

Machining hard materials, such as tool steel and tungsten carbide, involves high cutting forces and temperatures that lead to severe tool wear. Frequent tool changes owing to tool wear increase costs and decrease productivity, degrading the surface quality and accuracy of machined parts. Various studies have explored approaches to reduce tool wear in the machining of hard materials, such as micropatterns on the rake face of cutting tools, ultrasonic elliptical vibration cutting, and built-up-edge at the end of the tool. However, limited research has been conducted on the microstructures and patterns of the built-up edges. This study proposes a methodology to stabilize the built-up edge at the end of a tool with microstructures and patterns. The chip morphology and behavior were simulated using FEM software to determine the machining conditions and microstructure required to maintain a constant built-up edge at the tool tip. Several microstructures were machined at the edge of the cutting tool, and orthogonal cutting experiments were conducted to validate the simulation. Additionally, tool wear was evaluated for the tool structure and machining conditions.