Modeling and experimental investigation of edge hone and flank contact effects in metal cutting

In this study, a process model for orthogonal cutting is developed in order to determine the effect of the hone radius and flank contact on cutting forces. A thermo-mechanical model at primary shear zone with sticking and sliding contact zones on the rake face is used for cutting forces and these contact zones are implemented in the third deformation zone. The model predictions are verified by experiments using carbide inserts with various hone radii at different speeds and feeds.