Effect of tool nose profile tolerance on surface roughness in precision turning

Abstract

The effect of the tool nose profile deviations in cutting tool inserts on the surface roughness of the work piece produced based on the actual tool nose profile geometry is studied. The nose profile was detected from the tool nose image captured using the 3-D metrology system. A edge detection approach combining moment invariance operator with Sobel 2-D filter operator is proposed. A work piece surface profile is then generated by considering tool nose profile deviation, feed rate, nose radius and wedge angle to study the effect of the work piece geometry deviation on the roughness values. Based on the experimental results, the maximum differences from ideal and experimental results are 19.8% for Rt, 19.9% for Ra and 16.1% for Rq respectively. © 2012 Springer-Verlag.