HSS Forum’s International Conference « Smart solutions for metal cutting », Aachen, 2-3 February 2005

CUTTING EDGE PREPARATION AND SURFACE ISSUES

Joël RECH
Laboratory of Tribology and Systems Dynamics
Ecole Nationale d’Ingénieurs de Saint-Etienne, 42000 Saint-Etienne (France), joel.rech@enise.fr

“The micro designing of the cutting edge is an area requiring development, experience and advanced
manufacturing techniques” (Sandvik, 1994)

1. CONTEXT

The cutting process remains one of the most extreme applications in mechanics : extreme local
pressures between the tool and the workmaterial (100–10000 N/mm²), extreme temperatures (300-
1200°C), extreme velocities (1-30 m/s) (Trent, 1991). In this aggressive context, end users expect to
have more and more productivity in their machining processes (high removal rate of workmaterial) and
low wear of their cutting tools (long tool life). These demands require major improvements in the
design of cutting tools : new substrates, new coatings, etc. In parallel to the design of the macroscopic
specifications of such cutting tools (geometry, materials, etc.), tool manufacturers know that the
manufacturing procedures of their cutting tools, and especially the micro-geometry (roughness, cutting
edge preparation, etc.), have a major influence on their performance and on their reliability. This
aspect is especially of high importance for cutting tools destinated to mass production plants. The
consequences of the manufacturing procedure concern on the one hand the coating’s adhesion and
on the other hand the reinforcement of the cutting edge so as to avoid unpredictable cutting edge
chipping. The interest to manufacture a cutting edge preparation is known by experienced workers on
machine tools. They use to round edges by the application of a stone. Depending on the pressure
applied by the stone on the edge, the micro-geometry obtained was different so as to fit with the
application : rough turning of steels, finishing of aluminium, etc.. Depending on the worker, results
were also uncertain. The wide majority of the scientific investigations in that area were concerned by
carbide substrates, and more recently by c-BN substrates dedicated to hard machining applications.
However, the manufacturing procedures applied on HSS cutting tools is also of high importance
(Rech, 2004).
This paper will present some typical ways of producing cutting tools, and especially to manufacture the
micro-geometry of cutting edges. The typical problems faced by end users, regarding the reliability of
their cutting applications, will be treated through the analysis of some usual observable problems of
edge preparation. A state of the art of the scientific knowledge in that area will bring some
explanations on the parameters to consider when choosing a cutting tool. Finally, some industrial
applications of cutting edge preparation on HSS solid tools will illustrate the impressive potential
improvements of engineered cutting edges.

2. CUTTING TOOLS MANUFACTURING PROCEDURE AND THE CORRESPONDING CUTTING EDGE PREPARATION

Presenting all the manufacturing procedures used by every cutting tool producers is of course
impossible. The next paragraph will only introduce some standard production procedures and some
typical cutting edge preparation manufactured on carbide, c-BN and HSS substrates.

2.1. MANUFACTURING PROCEDURE OF CARBIDE INSERTS

One of the usual way of producing carbide inserts is illustrated by figure 1. After the well known
compression and sintering processes, the macroscopic geometry of the cutting tool is completed. This
macroscopic geometry includes the chip-breaker close to the edge of the insert, especially for
continuous cutting application, such as turning.

After this step, the micro-geometry of the cutting edges may be calibrated by different processes,
depending on the expected result :
• Grinding of the rake face so as to get sharp edges (cutting edge radii < 5 µm)

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HSS Forum’s International Conference « Smart solutions for metal cutting », Aachen, 2-3 February 2005

• Micro-sandblasting of the rake and flank faces so as to get intermediate edges (radii ~ 5 – 20
µm)
• Brushing of the edges so as to get large edges (radii up to 50 µm)

Edge Post
Compres. Sinter. Coating
Prep. Treat.

Macro- Micro- Wear Surface

geometry Geometry : resistance texture
edge radius,
surface texture

brushing

Fig. 1 : Example of manufacturing procedure of a carbide insert

Figure 2 illustrates some standard chip-breaking geometry and cutting edge radius (edge preparation)
manufactured on the one hand on a turning carbide insert for the roughing of steel, and on the other
hand for the finishing of aluminium alloys. The difference of geometry is easily understandable,
because of the large difference of hardness of each workmaterial, and because of the large difference
of tool-chip contact area (large chip thickness in roughing Ù small chip thickness in finishing).

rough turning of steels finish turning of alum.

Fig. 2 : Comparison of the edge preparation and of the chip-breaker on two carbide inserts

2.2. MANUFACTURING PROCEDURE OF C-BN INSERTS

The design of the micro-geometry of c-BN inserts for hard machining operation is rather different from
the previous case. First of all, the hard turning process is only concerned by finishing with very small
feed rates (small chip thickness). As a consequence the mechanical stresses close to the edge are
much higher. Moreover, the bending strength of c-BN inserts is much inferior than the one of carbide
substrates (570 MPa Ù 1600 MPa). Under such conditions, the micro-geometry of the cutting edges

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must induce compressive stresses inside the substrate, and these stresses should be orientated in the
bulk material. Figure 3 illustrates some typical solutions applied by c-BN tool manufacturers. Large
cutting edge preparation, associated with large radii or chamfer, are a usual way to strengthen such
brittle cutting tools submitted to high loads.

Chamfered edge Chamfered + Double-

honed edge chamfered edge

Fig. 3 : Some typical edge preparation on c-BN inserts

2.3. MANUFACTURING PROCEDURE OF SOLID TOOLS

The manufacturing procedure of solid tools is better known by end users, since a large number of
them have to care about the resharpening of their expensive cutting tools such as hobs, broaches,
saw blades, etc. Usually small solid tools are directly ground from bars of carbide or pre-hardened
HSS. The cutting edge preparation is usually made by micro-sandblasting (figure 4) or by brushing.
Cutting edge radii are usually much smaller for HSS tool than the one applied on carbide tools,
because of the higher bending strength (4800 MPa Ù 1600 MPa).

Edge Post
Grind. Coating
Prep. Treat.

Macro- Micro- Wear Surface

geometry Geometry : resistance texture
edge radius,
surface texture

Micro-sandblasting :
Al2O3 grains
Mesh 400 – 600
Pressure 2 – 6 bars

Fig. 4 : Example of manufacturing procedure on a solid tool

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HSS Forum’s International Conference « Smart solutions for metal cutting », Aachen, 2-3 February 2005

round edge
Sharp edge 50 µm ~ 10 µm
50 µm

Fig. 5 : Example of cutting edge micro-geometry on a HSS hob

round edge
~ 10 µm Sharp edge

Fig. 6 : Example of cutting edge micro-geometry on a carbide end-mill

3. USUAL MICRO-GEOMETRICAL DEFECTS OF CUTTING TOOLS

When inspecting the micro-geometry of cutting tools, and especially of solid tools, one can observe a
large variety of defects such as : micro-breakages, burrs, burns, lack of coatings, poor surface
roughness, etc. These observations can be made irrespective of the substrate (HSS or carbide) and
irrespective of the tool manufacturer.

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• Micro-breakages are mainly due to the grinding process and to the handling between each
step of the manufacturing procedure (Fig. 7 & 8). It should be underlined that the micro-
breakages may occur as well before or after the coating phase.
• Burrs are only due to the grinding process (Fig. 7 & 8). It is very important to notice that the
presence of burrs on cutting edges is very problematic for the edge preparation process, since
it disturbs the reliability of its result. Few scientific publications dealing with the influence of the
grinding conditions on burr formation on cutting tools have treated this question.
• Poor surface roughnesses observed on some faces are due to bad grinding conditions (see
previous Fig. 9). When the surface textures are very bad (especially when big waves are
observable), the edge preparation process can not improve the micro-geometry sufficiently
and the result will not be satisfactory.

Usual point of view

on a cutting tool ~
macroscopic scale

HSS Cutting edge breakage HSS Burrs

after coating

CARBIDE

Cutting edge breakage

before coating

Fig. 7 : Typical defects observed on solid end mills

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HSS HSS

Cutting edge breakage

Burrs before coating

Fig. 8 : Typical defects observed on solid hobs

+2 µm +2 µm

Roughness
profiles
-3 µm -3 µm

roughness Ra ~ 0.3 µm roughness Ra ~ 1.0 µm

Fig. 9 : Comparison between a new and a resharpened hob

4. THE CUTTING EDGE PREPARATION IN THE SCIENTIFIC LITERATURE

The effect of cutting edge geometry has long been an issue in understanding metal cutting. In his
analytical modelling of the orthogonal cutting process, (Merchant, 1945) clearly indicated the
assumption of tool sharpness. Nevertheless, the edge of a real tool always has a finite sharpness,
however small. There is an understanding, however, that the machining force trends will be different
for a sharp tool as compared to those of a blunt tool, with all else being held constant (Schimmel,
2002) (Fang, 2003) (Rech, 2004).

The research works aiming to introduce this parameter dates back to the 1950-1960s (Becker, 1952)
(Thomsen, 1953) (Albrecht, 1960). The ratio of edge radius to the uncut chip thickness has been used

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by some investigators as a measure of whether or not the tool should be treated as sharp or blunt. The
term ‘size effect’ has been introduced (figure 10). One phenomenon closely related to the effect of the
edge rounding is the apparent increase in specific energy (the ratio of the cutting force to the cross-
sectional area of cut, in N/mm²) required to form a chip as the uncut chip thickness is decreased
(Nakayama, 1968).

Fig. 10 : Illustration of the size effect

Since few years now, the effect of tool edge roundness attracts growing attention from the
international machining research community due to ever accelerating applications of precision, micro-,
and nano-machining technologies in a wide variety of modern industries :
• Finish turning of hard materials in automotive and aircraft industries (Thiele, 1999)
• Wafer fabrication (Li, 2003)
• Finish turning of aluminium alloys (Yuan, 1996)
• Etc.

The design of the cutting edge preparation has been investigated on the one hand by some research
academic laboratories, but on the other hand it has mainly been studied by tool manufacturers,
through a huge number of machining tests. As a consequence, the scientific explanations of the key
parameter controlling this problem remain unclear.

Among the published research who have recently investigated the effects of cutting edge preparation
on the performance of cutting tools, the micro-sandblasting process was the most popular process,
since it is a basic and cheap process (Klocke, 1999)(Bouzakis, 2002)(Bradbury, 2000)(Knotek,
1992)(Tonshoff, 1997). These authors have shown that the micro-sandblasting can improve the tool
life either in turning, drilling, sawing and milling of carbon steels. The sandblasting process delays the
apparition of coating’s failure and leads to a more homogeneous wear This mechanical treatment
seems to be much more efficient than other processes such as polishing.

(Bouzakis, 2001)(Bouzakis, 2002) has investigated in details the micro-sandblasting treatment on

cemented carbides. He has reported that the micro-sandblasting process can be used to reduce high
roughness peaks, to obtain low mean spacing between roughness profile peaks as well as to remove
the binding material cobalt and to improve hereby the coating adhesion. In milling of steels, he has
observed that the honing process seems to be much more efficient than the micro-sandblasting
process in the same order of magnitude of radius. He explained this worse behaviour of the micro-
sandblasting treatment by the removal of carbide grains on the outer surface by the sand jet.

In parallel, authors have investigated the consequences of the cutting edge preparation on the chip
formation so as to bring informations to the understanding of the cutting performance of a specific
treatment :
• By investigating the influence of two cutting edge radii (2 and 25 µm) in orthogonal turning of a
carbon steel with a CCD camera, (M’Saoubi, 2004) has revealed that a high radius induces an
increase of around 15°C of the maximum cutting temperature on the rake face. Since this
author, the influence of a radius on the thermal aspects of the cutting process seems to be of
secondary importance.
• (Rech, 2004) (Schimmel, 2002) have shown through experimental investigations in orthogonal
turning, that the thrust force is much more sensitive to the edge radius than the cutting force
(more than two times more sensitive). (Fang, 2003) has obtained similar conclusions from an
analytical investigations based on a slip-line model.
• (Fang, 2003) has shown that the tool-chip frictional shear stress around the edge is a very
important parameter which influences the optimum edge radius for each application. He
reveals that the chip thickness decreases with the increase of the cutting edge radius. The

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tool-chip contact length decreases significantly. The average shear strain in the primary shear
zone and the corresponding strain rate are very significantly affected.
• (Bouzakis, 2002) proposed to attribute the variation of wear resistance in milling of carbide
inserts with varius edge radii to the fatigue resistance of the coating. He tried to evaluate the
mechanical stresses in the region of the edge radius so as to quantify the mechanical load
supported by the coating for each radius. The maximum von Mises equivalent stress
developed appears on the cutting edge roundness close to the flank (result confirmed by
(Rech, 2004)). Inserting the determined stresses into the examined coating Woehler diagram
(~ Fatigue resistance versus the von Mises equivalent stress), he shows a good agreement
between the predicted fracture of the coating and the tool life of the corresponding insert.
• (Rech, 2004) has conducted finite element analysis in orthogonal turning of steels with various
cutting edge radii. It has been shown that an optimum cutting edge radius exists so as to
minimize the von Mises stresses around the cutting edge, and especially in the coating layer.
Moreover milling tests have confirmed that the optimum cutting edge radius found
experimentally is of the same order of magnitude as in the case of FEA analysis. It seems to
confirm that the minimization of the von Mises Stresses inside the coating is a good way to
maximize the wear resistance of a cutting tool.

Since these studies, it seems that the edge radius manufactured on a cutting tool affects the chip
formation. It also changes more the feed force than the cutting force. It affects a lot the tool-chip
contact area. These phenomena seem to lead to small variations on the thermal fields but to important
variations on the mechanical stresses around the edge, especially in the coating layer. The
minimization of the von Mises stresses inside the coating seems to be a key parameter to maximize
the tool life duration. The optimum value depends on a large number of parameters as summarized by
figure 11. It depends on the mechanical properties of the workmaterial, on the mechanical properties
of the substrate and of the coating, but also on the cutting conditions (roughing Ù turning).

Workmaterial : Substrate :
• composition • composition
• hardness,
hardness, etc. • hardness,
hardness, etc.
Tool

Workpiece

Coatings : Cutting conditions :

• adhesion spec.
spec. • feed rate
• depth of cut.
cut.

Fig. 11 : Comparison between a new and a resharpened hob

5. SOME INDUSTRIAL APPLICATION OF CUTTING EDGE PREPARATION ON HSS SOLID TOOLS

5.1. MILLING WITH A (66 HRC) PM-HSS END-MILL

A set of cutting tools with various edge radii have been manufactured based on a ASP2052 substrate
and on a TiAlN coating. The radii have been obtained by micro-sandblasting or honing. The
investigations were performed using a 3-axis numerically controlled milling centre. The workmaterial is
a 27MnCr5 steel (180 HB). The radial depth of cut ae and the axial depth of cut ap have been
remained constant, respectively 10 and 2.5 mm. The following cutting conditions have been applied :
Vc = 100 m/min – fz = 0.3 mm/rev – max. chip thickness = 0.24 mm. All tests have been performed in
dry cutting conditions and duplicated. The tool life criterion for these wear tests was a maximum flank
wear VBmax of 0.15 mm, owing to the large increase in the wear rate over this value, which may lead

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HSS Forum’s International Conference « Smart solutions for metal cutting », Aachen, 2-3 February 2005

to unreliable results. Figure 12 presents the results obtained. In this figure, the effective cutting edge
radius (R) is referred to as the radius of the substrate edge without coating
First, it is remarkable to see that the inserts with a cutting edge radius of 10 µm exhibit a better wear
resistance. On the other hand, the sharper inserts and the rounder inserts have a much worse
behaviour. The existence of an optimum edge radius can be explained by the minimization of the von
Mises stresses inside the coating.
When comparing a standard ground end-mill, similar to a large majority of PM-HSS tools available on
the market, and a tool “mechanically treated” with a radius of 10 µm, one can observe an improvement
of between 400 to 500% in the tool life.

120

100

VBmax = 0.15 mm
Tool life (min.) 80

60

40
Substrate : PM-HSS (66 HRc)
20
Coating : TiAlN
0
Workmaterial : 27MnCr5 (180HB) 0 20 40 60 80

Cutting edge radius (µm)

Fig. 12 : Influence of the cutting edge radius in milling with a PM-HSS end-mill (66HRc)

5.2. MILLING WITH A (70 HRC) PM-HSS END-MILL

Similar cutting tools as previously have been manufactured, but with a different PM-HSS substrate
allowing a higher hardness (70 HRc). The testing conditions were similar.
Figure 13 shows that such a harder substrate has a very different behaviour. The larger radii lead to
much better results than small radii. This may be explained by the completely different mechanical
properties of a harder HSS. The decrease of the bending strength with the hardness necessitates to
shift the optimum cutting edge radius. It can be assumed that radii over 60 µm can decrease the wear
resistance of the tools.
160
140
VBmax = 0.15 mm

120
Tool life (min.)

100
80
60
40
Substrate : PM-HSS (70 HRc)
20
Coating : TiAlN 0
0 20 40 60 80
Workmaterial : 27MnCr5 (180HB)
Cutting edge radius (µm)

Fig. 13 : Influence of the cutting edge radius in milling with a PM-HSS end-mill (70HRc)

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HSS Forum’s International Conference « Smart solutions for metal cutting », Aachen, 2-3 February 2005

5.1. HIGH SPEED DRY GEAR HOBBING

Gear hobbing remains a cutting technology where high speed steels continue to find wide applications
in modern manufacturing practice. The investigation of the influence of cutting edge preparation is
problematic due to the very long duration of wear tests. However the application of an analogy process
called “fly hobbing” has shown its efficiency to classify various solutions with a similar trend as the real
hobbing process, but with a much faster and cheaper way.
For this investigation, a set of modulus 2 ‘fly cutters’ with various edge radii have been manufactured
based on a ASP2052 substrate (66 HRc) and on a TiAlN coating. The radii have been obtained by
micro-sandblasting or honing. The workmaterial is a 27MnCr5 steel (270 HB). The following cutting
conditions have been applied : Vc = 140 m/min – max. chip thickness = 0.3 mm. All tests have been
performed in dry cutting conditions and duplicated. The tool life criterion for these wear tests was a
maximum flank wear VBmax of 0.1 mm, owing to the large increase in the wear rate over this value,
which may lead to unreliable results. Figure 14 presents the results obtained. In this figure, the
effective cutting edge radius (R) is referred to as the radius of the substrate edge without coating
First, it is remarkable to see that the fly cutters with a cutting edge radius of 20 µm exhibit a better
wear resistance. On the other hand, the sharper cutters and the rounder cutters have a much worse
behaviour. As previously, the existence of an optimum edge radius can be explained by the
minimization of the von Mises stresses inside the coating.

100
90
Analogy process : 80
fly hobbing
Nb of gears produced

70
( VBmax = 0.1 mm )

60
50
40
30
20
10
0
Tool : PM-HSS fly hob (70 HRc)
Coating : TiAlN 0 10 20 30 40
Workmaterial : 27MnCr5 (270HB) Cutting edge radius (µm)

Cutting speed : 140 m/min

Chip thickness : 0.3 mm
Modulus : 2

Fig. 14 : Influence of the cutting edge radius in gear hobbing

6. CONCLUSIONS

This paper has shown the necessity to consider the micro-geometry of cutting tools when choosing a
cutting tool for a defined application. The optimum micro-geometry depends on several parameters
such as : the cutting application, the properties of the materials of the tool, the properties of the
workmaterial, the chip thickness, etc. All the substrates are concerned by this problem, even in the
case of HSS tools, on which traditionally few edge preparations are applied. Moreover, due to the
manufacturing procedure on solid tools and especially on HSS solid tools, micro-geometrical defects
can be easily observed on cutting edges when no edge preparation is used. Some examples of cutting
edge preparation on HSS end mills and on HSS roughing hobs have shown that impressive
improvements of the wear resistance can be reached.

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7. REFERENCES

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(Tonshoff, 1997) H.K.Tonshoff, C.Blawit, Influence of surface integrity on performance of coated

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