Manufacturing and
Materials Processing
Journal of
Article
FE-Simulation Based Design of Wear-Optimized Cutting
Edge Roundings
Benjamin Bergmann
1
, Berend Denkena
1
, Sascha Beblein
2
and Tobias Picker
1,
*
Citation: Bergmann, B.; Denkena, B.;
Beblein, S.; Picker, T. FE-Simulation
Based Design of Wear-Optimized
Cutting Edge Roundings. J. Manuf.
Mater. Process. 2021, 5, 126. https://
doi.org/10.3390/jmmp5040126
Academic Editors: Arkadiusz Gola,
Izabela Nielsen and Patrik Grznár
Received: 1 November 2021
Accepted: 22 November 2021
Published: 25 November 2021
Publisher’s Note: MDPI stays neutral
with regard to jurisdictional claims in
published maps and institutional affil-
iations.
Copyright: © 2021 by the authors.
Licensee MDPI, Basel, Switzerland.
This article is an open access article
distributed under the terms and
conditions of the Creative Commons
Attribution (CC BY) license (https://
creativecommons.org/licenses/by/
4.0/).
1
Institute of Production Engineering and Machine Tools, Leibniz University Hannover, An der Universität 2,
30823 Garbsen, Germany; bergmann@ifw.uni-hannover.de (B.B.); denkena@ifw.uni-hannover.de (B.D.)
2
LMT Tools GmbH & Co. KG, Grabauer Str. 24, 21493 Schwarzenbek, Germany;
Sascha.Beblein@LMT-Group.NET
* Correspondence: picker@ifw.uni-hannover.de; Tel.: +49-511-762-4299
Abstract:
The performance of cutting tools can be significantly enhanced by matching the cutting edge
rounding to the process and material properties. However, the conventional cutting edge rounding
design is characterized by a significant number of experimental machining studies, which involve
considerable cost, time, and resources. In this study, a novel approach to cutting edge rounding design
using FEM-based chip formation simulations is presented. Based on a parameterized simulation
model, tool temperatures, stresses and relative velocities can be calculated as a function of tool
microgeometry. It can be shown that the external tool loads can be simulated with high agreement.
With the help of these loads and the use of wear models, the resulting tool wear and the optimum
cutting edge rounding can be determined. The final experimental investigations show a qualitatively
high agreement to the simulation, which will enable a reduced effort design of the cutting edge in
the future.
Keywords: FE simulation; cutting edge roundings; wear simulation
1. Introduction
Cutting edge preparation is state of the art in the manufacture of cutting tools. Knowl-
edge of the influence of microgeometry on the application behavior of cutting tools plays a
key role in a complete understanding of the process [
1
]. Cutting edge microgeometry is
commonly described as an ideal arc with a radius of r
β
. However, further investigations
of rounded cutting edges depicted a symmetrical or asymmetrical shape. Denkena et al.
developed the form-factor method (see Figure 1), which describes not only symmetrical
but also asymmetrical cutting edge roundings with the parameters S
α
, S
γ
,
∆
r, K and
ϕ
[
2
].
J. Manuf. Mater. Process. 2021, 5, x. https://doi.org/10.3390/xxxxx www.mdpi.com/journal/jmmp
Article
FE-Simulation Based Design of Wear-Optimized Cutting Edge
Roundings
Benjamin Bergmann
1
, Berend Denkena
1
,
Sascha Beblein
2
and Tobias Picker
1,
*
1
Institute of Production Engineering and Machine Tools, Leibniz University Hannover, An der Universität 2,
30823 Garbsen, Germany; bergmann@ifw.uni-hannover.de (B.B.); denkena@ifw.uni-hannover.de (B.D.)
2
LMT Tools GmbH & Co. KG, Grabauer Str. 24, 21493 Schwarzenbek, Germany;
Sascha.Beblein@LMT-Group.NET
* Correspondence: picker@ifw.uni-hannover.de; Tel.: +49-511-762-4299
Abstract: The performance of cutting tools can be significantly enhanced by matching the cutting
edge rounding to the process and material properties. However, the conventional cutting edge
rounding design is characterized by a significant number of experimental machining studies, which
involve considerable cost, time, and resources. In this study, a novel approach to cutting edge
rounding design using FEM-based chip formation simulations is presented. Based on a parameter-
ized simulation model, tool temperatures, stresses and relative velocities can be calculated as a func-
tion of tool microgeometry. It can be shown that the external tool loads can be simulated with high
agreement. With the help of these loads and the use of wear models, the resulting tool wear and the
optimum cutting edge rounding can be determined. The final experimental investigations show a
qualitatively high agreement to the simulation, which will enable a reduced effort design of the
cutting edge in the future.
Keywords: FE simulation; cutting edge roundings; wear simulation
1. Introduction
Cutting edge preparation is state of the art in the manufacture of cutting tools.
Knowledge of the influence of microgeometry on the application behavior of cutting tools
plays a key role in a complete understanding of the process [1]. Cutting edge microgeom-
etry is commonly described as an ideal arc with a radius of r
β
. However, further investi-
gations of rounded cutting edges depicted a symmetrical or asymmetrical shape. Denkena
et al. developed the form-factor method (see Figure 1), which describes not only symmet-
rical but also asymmetrical cutting edge roundings with the parameters S
α
, S
γ
, ∆r, K and
φ [2].
Figure 1. Characterization of the cutting edge microgeometry [2].
Citation: Bergmann, B.; Denkena, B.;
Beblein, S.; Picker, T. FE-Simulation
Based Design of Wear-Optimized
Cutting Edge Roundings. J. Manuf.
ater. Process. 2021, 5, x.
https://doi.org/10.3390/xxxxx
Academic Editors: Arkadiusz Gola,
Izabela Nielsen and Patrik Grznár
Received: 1 November 2021
Accepted: 22 November 2021
Published: 25 November 2021
Publisher’s Note: MDPI stays neu-
tral with regard to jurisdictional
claims in published maps and insti-
tutional affiliations.
Copyright: © 2021 by the authors.
Submitted for possible open access
publication under the terms and
conditions of the Creative Commons
Attribution (CC BY) license
(http://creativecommons.org/li-
censes/by/4.0/).
Figure 1. Characterization of the cutting edge microgeometry [2].
The interactions between the tool properties, the cutting parameters and the effects
on the machining process are all influenced and thus determined by the cutting edge
J. Manuf. Mater. Process. 2021, 5, 126. https://doi.org/10.3390/jmmp5040126 https://www.mdpi.com/journal/jmmp
