Predictability of tool failure modes in turning with complex grooved toolsusing the equivalent toolface (ET) model

This paper presents a new methodology for predicting the most dominant tool failure modes in turning with complex grooved tools. Predictions are made using a newly developed equivalent toolface (ET) model. The changes in cutt ing conditions and chip-groove geometry are reflected in the cutting forces . The ET model predicts the 'equivalent flat-faced' tool geometry from the cutting forces in terms of the effective inclination and rake angles. The d ominant modes of tool failure are established from an analysis of the ET ge ometry. Thus, tool failure is related to the initial cutting forces and thi s is verified from experimental results using different chip-groove geometr ies for a range of cutting conditions and a given tool/work material combin ation. (C) 2000 Elsevier Science S.A. All rights reserved.