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Electro-erosion edge honing
of cutting tools N. Z. Yussefian, P. Koshy McMaster University, Canada S. Buchholz, F. Klocke RWTH Aachen University, Germany This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site: Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.” Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004). ___________________________________________ *You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source.
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Edge preparation of cutting tools
~ µm chamfer hone tool chip work Influences chip formation Affects surface integrity Precludes catastrophic tool failure Enhances tool life & coatability Ensures consistent tool performance nose radius edge radius measured in X-X plane This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site: Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.” Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004). ___________________________________________ *You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source. Electro-erosion edge honing of cutting tools N.Z. Yussefian, P. Koshy, S. Buchholz, F. Klocke 60th CIRP General Assembly Pisa, August 25, 2010
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Influence of edge radius on carbide inserts
An increase in edge radius from 8 µm to 35 µm Delay in the onset of coating fracture Four-fold improvement in tool life Bouzakis et al (2002) This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site: Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.” Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004). ___________________________________________ *You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source. Electro-erosion edge honing of cutting tools N.Z. Yussefian, P. Koshy, S. Buchholz, F. Klocke 60th CIRP General Assembly Pisa, August 25, 2010
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Enhancement in high speed steel tool life
Rech et al (2005) This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site: Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.” Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004). ___________________________________________ *You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source. Edge honing enhanced the life of ground tools by ~400% Existence of an optimal cutting edge radius Electro-erosion edge honing of cutting tools N.Z. Yussefian, P. Koshy, S. Buchholz, F. Klocke 60th CIRP General Assembly Pisa, August 25, 2010
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Edge honing processes brush honing micro blasting
brush honing As high as ~50% variability in edge radius (Schimmel et al, 2000) Variability between edges as well as along the same edge Manufacturers hence generally specify edge hones in a range Somewhat limited when processing polycrystalline diamond tools This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site: Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.” Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004). ___________________________________________ *You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source. Electro-erosion edge honing of cutting tools N.Z. Yussefian, P. Koshy, S. Buchholz, F. Klocke 60th CIRP General Assembly Pisa, August 25, 2010
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Possibility of honing cutting edges by sink EDM
Edge rounding in EDM tool wear in EDM rounded edges Possibility of honing cutting edges by sink EDM This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site: Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.” Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004). ___________________________________________ *You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source. hone sharp honing Electro-erosion edge honing of cutting tools N.Z. Yussefian, P. Koshy, S. Buchholz, F. Klocke 60th CIRP General Assembly Pisa, August 25, 2010
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Electro-erosion edge honing
Honing of tools by sinking them into an appropriate counterface The high level of precision in EDM could address the variability issue Tools could be processed irrespective of material hardness counterface tool The volume of material removal associated with hone generation is very minimal The relatively low material removal rate of sink EDM is of little consequence Conservative EDM parameters may be employed with a view to preserving the integrity of the surface This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site: Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.” Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004). ___________________________________________ *You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source. Electro-erosion edge honing of cutting tools N.Z. Yussefian, P. Koshy, S. Buchholz, F. Klocke 60th CIRP General Assembly Pisa, August 25, 2010
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Kinematic configurations
tool counterface feed symmetric hone X Y Z asymmetric hone rotation of tool about Z axis increasing radius along the edge rotation about X axis This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site: Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.” Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004). ___________________________________________ *You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source. Electro-erosion edge honing of cutting tools N.Z. Yussefian, P. Koshy, S. Buchholz, F. Klocke 60th CIRP General Assembly Pisa, August 25, 2010
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Experimental Proof of concept & shape evolution
AISI T-15 High Speed Steel Aluminum counterface Finish ground SNEA 320 inserts 10 mm edge length; 90° wedge angle Dielectric oil; no external flushing average voltage 80 V peak current 1.8 A polarity tool (−) pulse on-time 0.6 µs duty factor 50% machining time 80 s This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site: Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.” Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004). ___________________________________________ *You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source. Proof of concept & shape evolution Assessment of tool performance & edge geometry Electro-erosion edge honing of cutting tools N.Z. Yussefian, P. Koshy, S. Buchholz, F. Klocke 60th CIRP General Assembly Pisa, August 25, 2010
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circular regression on profile data
Measurement of edge radius NURBS model point cloud data circular regression on profile data This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site: Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.” Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004). ___________________________________________ *You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source. confocal microscope Electro-erosion edge honing of cutting tools N.Z. Yussefian, P. Koshy, S. Buchholz, F. Klocke 60th CIRP General Assembly Pisa, August 25, 2010
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Effect of counterface material on edge geometry
cutting edge counterface Aluminum counterface Honed edge Wear ratio = 0.5 Copper counterface Chamfered edge Wear ratio = 7.5 This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site: Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.” Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004). ___________________________________________ *You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source. Electro-erosion edge honing of cutting tools N.Z. Yussefian, P. Koshy, S. Buchholz, F. Klocke 60th CIRP General Assembly Pisa, August 25, 2010
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Geometric simulation of electro-erosion honing
electrode feed to restore gap width material removal from electrodes as per wear ratio sparking across closest gap This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site: Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.” Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004). ___________________________________________ *You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source. Electro-erosion edge honing of cutting tools N.Z. Yussefian, P. Koshy, S. Buchholz, F. Klocke 60th CIRP General Assembly Pisa, August 25, 2010
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Comparison of simulation with experiment
wear ratio = 0.5 wear ratio = 7.5 This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site: Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.” Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004). ___________________________________________ *You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source. Electro-erosion edge honing of cutting tools N.Z. Yussefian, P. Koshy, S. Buchholz, F. Klocke 60th CIRP General Assembly Pisa, August 25, 2010
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Mechanism of edge generation
chamfer “high” wear ratio tool counterface hone This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site: Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.” Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004). ___________________________________________ *You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source. “low” wear ratio Electro-erosion edge honing of cutting tools N.Z. Yussefian, P. Koshy, S. Buchholz, F. Klocke 60th CIRP General Assembly Pisa, August 25, 2010
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Concept of a threshold wear ratio
A wear ratio much higher than the threshold results in the generation of a chamfer A wear ratio much lower than the threshold results in extensive in-feed of the tool into the counterface tool counterface s rβ feed β For β = 90°, rβ = 40 µm & s = 15 µm, threshold wear ratio = 0.4 This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site: Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.” Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004). ___________________________________________ *You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source. wear ratio = (Vt /Vc) Electro-erosion edge honing of cutting tools N.Z. Yussefian, P. Koshy, S. Buchholz, F. Klocke 60th CIRP General Assembly Pisa, August 25, 2010
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Electro-erosion honed surfaces
200 µm high speed steel ground EE-honed cemented carbide This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site: Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.” Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004). ___________________________________________ *You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source. extensive in-feed of cutting edge into counterface (wear ratio ~ 0.01) Electro-erosion edge honing of cutting tools N.Z. Yussefian, P. Koshy, S. Buchholz, F. Klocke 60th CIRP General Assembly Pisa, August 25, 2010
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Greater rate of recession
Time evolution of edge geometry fit circle Absolute radial deviation from fit circle is ~5% of edge radius 120 s (rβ = 40 µm) ground edge 60 s (rβ = 33 µm) 30 s (rβ = 22 µm) tool work b a Concept of relative duty (Crookall & Fereday, 1973) Greater rate of recession on b-b compared to a-a This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site: Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.” Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004). ___________________________________________ *You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source. Electro-erosion edge honing of cutting tools N.Z. Yussefian, P. Koshy, S. Buchholz, F. Klocke 60th CIRP General Assembly Pisa, August 25, 2010
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Comparison of tool life
Variable speed tool life test (Armarego & Brown, 1969) 20 25 30 35 40 45 50 1 10 100 Tool life (min) Cutting speed (m/min) EE-honed edge ground edge Annealed AISI 1045; dry cutting 0.15 mm feed; 0.5 mm depth of cut 300 µm max. flank wear tool life criterion Significant increase in tool life due to: Electro-erosion edge honing offsetting the negative influence of grinding-induced micro-chipping Reduction in the maximum tool temperature on account of enhanced heat transfer associated with larger contact area This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site: Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.” Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004). ___________________________________________ *You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source. Electro-erosion edge honing of cutting tools N.Z. Yussefian, P. Koshy, S. Buchholz, F. Klocke 60th CIRP General Assembly Pisa, August 25, 2010
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Variability in edge geometry
1 2 3 4 5 6 25 30 35 40 45 Edge radius (µm) Edge number Boxes and whiskers refer to 25/75 and 1/99 percentiles, respectively 140 measurements over an edge length of 10 mm (edge 1 above) indicated a mean of 32.1 µm and standard deviation of 1.6 µm, which refers to a variability of ~15% This is a significant improvement over conventional processes wherein the corresponding variability could be on the order of 50% about the mean radius This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site: Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.” Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004). ___________________________________________ *You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source. Electro-erosion edge honing of cutting tools N.Z. Yussefian, P. Koshy, S. Buchholz, F. Klocke 60th CIRP General Assembly Pisa, August 25, 2010
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Conclusions The application of electrical spark discharges for edge honing has been demonstrated The counterface material plays a critical role in the geometry of the generated edge Edge hones generated by electro-erosion honing significantly improved the life of ground tools Electro-erosion honing corresponds to robust edge geometry generation as compared to conventional processes This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site: Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.” Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004). ___________________________________________ *You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source. Electro-erosion edge honing of cutting tools N.Z. Yussefian, P. Koshy, S. Buchholz, F. Klocke 60th CIRP General Assembly Pisa, August 25, 2010
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Thank you for your kind attention!
Canadian Network of Centers of Excellence C4 Consortium of Ontario This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site: Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.” Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004). ___________________________________________ *You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source. Electro-erosion edge honing of cutting tools N.Z. Yussefian, P. Koshy, S. Buchholz, F. Klocke 60th CIRP General Assembly Pisa, August 25, 2010
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