Predictability of tool failure modes in turning with complex grooved tools using 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 cutting 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 dominant modes of tool failure are established from an analysis of the ET geometry. Thus, tool failure is related to the initial cutting forces and this is verified from experimental results using different chip-groove geometries for a range of cutting conditions and a given tool/work material combination.