The micro-geometry of the cutting tool significantly affects the process forces, thermal load, tool wear, and quality of the finished surface and chip characteristics. The effect of edge radius on the thermo-mechanical load for varying uncut chip thickness is studied during turning AISI 4340. A multi-sensor approach is used to measure the temperature at the flank face, the average temperature of the chip in the cutting zone and also at the free surface of the chip simultaneously by using a thermocouple, a thermal camera and a pyrometer respectively. A novel tool-chip contact area based analysis is used to delineate the effect of hone radius and nose radius separately. The major and minor cutting edge contact areas along the hone region are found to play a key role in influencing the process forces and temperature at different feeds. FEM simulations are conducted to study the effect caused by edge radius on the material flow in the stagnation and ploughing zones. Also, a linear regression analysis is carried out to predict the ideal cutting edge radius for different feeds used in this study − 0.1 mm/rev − 18 μm; 0.24 mm/rev − 33 μm; and 0.41 mm/rev − 43 μm. The results from this experimentation could be used by researchers to validate their temperature models and develop more accurate temperature maps of the tool.

切削刀具的微观几何形状会显着影响加工力，热负荷，刀具磨损以及精加工表面和切屑特性的质量。研究了AISI 4340车削过程中刃半径对变化的未切屑厚度的热机械载荷的影响。采用多传感器方法测量侧面的温度，切屑区域的平均温度和同时分别使用热电偶，热像仪和高温计在芯片的自由表面上。一种新颖的基于工具-芯片接触面积的分析被用来分别描绘出骨radius和鼻radius的影响。发现沿骨质区域的主要和次要切削刃接触区域在影响不同进料的加工力和温度方面起着关键作用。进行了有限元模拟，以研究边缘半径对停滞和耕作区物料流的影响。另外，进行了线性回归分析，以预测本研究中使用的不同进料的理想切削刃半径-0.1 mm / rev-18μm；0.24毫米/转-33微米; 和0.41 mm / rev-43μm。研究人员可以使用该实验的结果来验证他们的温度模型并开发更准确的工具温度图。