Prediction of milling tool edge honing in abrasive jet machining

Abstract

Edge honing is crucial in cutting tool production to enhance performance by removing micro defects and creating a honed edge profile. Wet abrasive jet machining (WAJM) is a popular method for edge honing, though challenging to observe due to the high abrasive impact speeds and small deformation areas. This study proposes a novel hybrid model to predict the WAJM-based edge honing process, revealing the relationship between WAJM parameters and the honed edge geometry of milling tools. The model begins from the non-uniform-distribution modeling of particle velocity and density using computational fluid dynamics (CFD). The material removal process for a single abrasive impacting a flat surface is calculated based on Hertz contact and kinetic energy theorem, and further refined to determine the material removal volume on a topographic surface by considering particle-surface contact points. By integrating CFD simulation results with an analytical model, the dynamic edge honing process is predicted using the Monte Carlo method. The model successfully simulates the transition from a sharp tool tip to a relatively rounded edge without predefined edge geometry. WAJM experiments on milling tools indicate excellent model performance, with a maximum Euclidean distance between predicted and measured curves of <1 µm. Additionally, the average prediction errors for edge segments on the rake face and flank face are 8% and 12.3%, respectively. The study thoroughly discusses the effects of nozzle pressure and traverse speed on edge geometry, providing valuable guidance for the cutting tool production.