Analysis of changes in angular coordinates of cutting tools when conducting technological operations under different cutting conditions

This study aims to optimize cutting conditions by controlling the working angles of cutting tools when machining shaped surfaces and changing operating parameters of the cutting process for technological reasons. The study object includes cutting conditions for machining shaped surfaces, their influence on the operating parameters of the cutting process, the working angles of cutting tools (rake angle and lead angle), and cutting edge inclination. When developing mathematical models, we used methods of the theory of cutting, analytical mechanics, and thermodynamics. Static and kinematic geometry analysis of a blade in a cutting tool showed that changes in the angular coordinates of the front surface of a blade require the introduction of controlled rotation axes when conducting technological operations under different cutting conditions. These axes should control the main blade angles, i.e., lead angle, rake angle, and cutting edge inclination. With more than 85% of the tool penetration, the working angles considerably change even when its installation errors are relatively small. It is proposed to introduce controlled rotation axes of the front surface of a blade in a cutting tool by its main angles, i.e., lead angle, rake angle, and cutting edge inclination. It is shown that working angles considerably change even when its installation errors are relatively small. The study revealed that these angles constructively limit the regulation range of the rake angle of a cutting tool due to the impermissible reduction of the back relief angle; these angles should be taken into account when calculating the power characteristics of the cutting process. Thus, in order to solve the problem of stabilizing the working angles of cutting tools, new methods and technologies should be developed, which would make it possible to control kinematic parameters in the cutting process more accurately. It is important to take into account the influence of various factors such as workpiece material, cutting tool type, and cutting conditions.

1. Kabaldin Yu.G., Bashkov A.A. Self-organization and friction mechanism under cutting. Russian Engineering Research. 2023;102(2):167-173. (In Russ.). https://doi.org/10.36652/0042-4633-2023-102-2-167-173. EDN: QPEWOW.

2. Kabaldin Yu.G., Sablin P.A., Sсhetinin V.S. Control of the dynamic stability of metal-cutting systems in the process of cutting based on the fractality of roughness of the machined surface. Frontier Materials & Technologies. 2023;3:43-51. (In Russ.). https://doi.org/10.18323/2782-4039-2023-3-65-4. EDN: PATDRX.

3. Bobrov V.F. Effect of tool main cutting edge inclination angle on metal cutting. Moscow: Mashgiz; 1962, 150 р. (In Russ.).

4. Bobrov V.F., Granovskij G.I., Zorev N.N., Isaev A.I., Klushin M.I., Larin M.N., et al. Development of the science of cutting metals. Moscow: Mashinostroenie; 1967, 416 р. (In Russ.). EDN: XVPBFT.

5. Bobrov V.F. Fundamentals of the theory of metal cutting.. Moscow: Mashinostroenie; 1975, 344 р. (In Russ.).

6. Wolf A.M. Metal cutting. Leningrad: Mashinostroenie; 1973, 496 р. (In Russ.).

7. Teleshevskij V.I., Sokolov V.A. Laser correction of geometric errors of multi-coordinate systems with software control. Measurement technology. 2012;5:33-37. (In Russ.).

8. Kuznetsov A.P. Thermal behavior and accuracy of metal-cutting machines. Moscow: Yanus-K; 2011, 255 р. (In Russ.).

9. Salnikov V.S., Shadsky G.V., Erzin O.A. Analysis of technical capabilities by kinematic angles of cutting wedge at turning. Proceedings of the Tula State University. Technical Science. 2023;12:276-284. (In Russ.). https://doi.org/10.24412/2071-6168-2023-12-276-277. EDN: RVCVLJ.

10. Erzin O.A., Shadsky G.V., Shatalov D.D. Control of cutter kinematic angles depending on machined part profile. Proceedings of the Tula State University. Technical Science. 2024;8:494-501. (In Russ.). https://doi.org/10.24412/2071-6168-2024-8-494-495. EDN: INPCGN.

11. Zakovorotny V., Gvindjiliya V. The features of the evolution of the dynamic cutting system due to the regenerative effect. In: Dynamics of technical systems: AIP Conference Proceedings of the 7 International Scientific-Technical Conference. 9–11 September 2023, Rostov-on-Don. Rostov-on-Don: American Institute of Physics Inc.; 2023, vol. 2507, Iss. 1, р. 030002. https://doi.org/10.1063/5.0109559. EDN: FLSYFX.

12. Bezyazychnyj V.F. Similarity method in mechanical engineering technology. Moscow: Infra-Inzheneriya; 2021, 356 р. (In Russ.).

13. Salnikov V.S., Shadsky G.V., Erzin O.A. Analysis of the design solution of an intelligent cutting tool with a controlled front angle. Proceedings of the Tula State University. Technical Science. 2022;10:400-406. (In Russ.). https://doi.org/10.24412/2071-6168-2022-10-400-406. EDN: IECIWG.

14. Shadsky G.V., Salnikov V.S., Erzin O.A. Analysis of technical capabilities by kinematic angles of cutting wedge at turning. Proceedings of the Tula State University. Technical Science. 2019;12:360-367. (In Russ.). EDN: AZLAUI.

15. Shadsky G.V., Salnikov V.S., Erzin O.A. Prospects of control of kinematic angles of cutting wedge at turning operations. Proceedings of the Tula State University. Technical Science. 2019;12:342-349. (In Russ.). EDN: PLHGSV.

16. Salnikov V.S., Shadsky G.V., Erzin O.A. Technical solution of a cutting turning tool with a controlled front angle. Proceedings of the Tula State University. Technical Science. 2024;2:3-6. (In Russ.). https://doi.org/10.24412/2071-6168-2024-2-3-4. EDN: YTQRUQ.

17. Evseev L.L. Initial provisions and dependencies for calculating metal cutting dynamics characteristics. Russian Engineering Research. 1995;12:3-7. (In Russ.).

18. Evseev L.L. Calculating optimal cutting speed based on chip formation dynamic coefficient. Machines and Tooling. 1994;4:41-43. (In Russ.).

19. Volkov D.I., Proskuryakov S.L. Development of process models including cutting cycle formation CHIP. Vestnik UGATU. 2011;15(3):72-78. EDN: PWTNTV. (In Russ.).

20. Ryzhkin A.A., Klimov M.M., Sergeev R.V. Chip formation features during steel processing by hard alloys with wear-resistant coatings. Vestnik of Don State Technical University. 2001;1(1):47-53. (In Russ.). EDN: SXQCTB.