Modeling cutting edge honing process in wet abrasive jet machining
(2025) In Journal of Manufacturing Processes 152. p.1275-1294- Abstract
Cutting edge preparation is crucial in metal cutting as the edge geometry significantly influences both the material removal process and tool life. However, an analytical model that can physically describe the cutting edge preparation process has not yet been established. Taking the wet abrasive jet machining (WAJM) method as an example, the following questions always remain: Why does WAJM always form a relatively rounded cutting edge? What is the relationship between the process parameters and cutting edge geometries? This study, for the first time, proposes an analytical model for WAJM-based cutting edge preparation that simulates the transition from a sharp edge to a honed one under various process parameters. The model is based on... (More)
Cutting edge preparation is crucial in metal cutting as the edge geometry significantly influences both the material removal process and tool life. However, an analytical model that can physically describe the cutting edge preparation process has not yet been established. Taking the wet abrasive jet machining (WAJM) method as an example, the following questions always remain: Why does WAJM always form a relatively rounded cutting edge? What is the relationship between the process parameters and cutting edge geometries? This study, for the first time, proposes an analytical model for WAJM-based cutting edge preparation that simulates the transition from a sharp edge to a honed one under various process parameters. The model is based on energy principles and impact trajectories, allowing the calculation of the machining ability of a single particle. By extending impact process from flat polishing to the machining process of a topographic surface, and by introducing micro-scale contact theory, the model can predict the formation process of honed edge. Extensive experiments on carbide and ceramic inserts have been done for a comprehensive validation. The maximum Euclidean distance Edmax between predicted and measured edge profile is within 1 μm. The average prediction error for cutting edge parameters (Sγ, Sα and K) are below 10 %. For the depth of machining layers on rake and flank faces (Dr and Df), errors are below 15 %. Building upon this foundation, the study elucidates the influence of the traverse speed and jet angle on the geometry of the cutting edge. The established model interprets the abrasive impact and cutting edge formation mechanisms of WAJM-based cutting edge preparation process, offering effective guidance for tool manufacturers to precisely control the cutting edge geometry.
(Less)
- author
- Yang, Yan ; Weng, Jian LU ; Xu, Dongdong ; Zhou, Jinming LU ; M'Saoubi, Rachid LU and Zhuang, Kejia
- organization
- publishing date
- 2025-10
- type
- Contribution to journal
- publication status
- published
- subject
- keywords
- Analytical model, Cutting edge preparation, Overlapping impact, Wet abrasive jet machining
- in
- Journal of Manufacturing Processes
- volume
- 152
- pages
- 20 pages
- publisher
- Elsevier
- external identifiers
-
- scopus:105014595460
- ISSN
- 1526-6125
- DOI
- 10.1016/j.jmapro.2025.08.071
- language
- English
- LU publication?
- yes
- id
- 995b417d-4f6c-47aa-9245-1ef1678873ce
- date added to LUP
- 2025-10-09 13:12:33
- date last changed
- 2025-10-14 13:03:52
@article{995b417d-4f6c-47aa-9245-1ef1678873ce,
abstract = {{<p>Cutting edge preparation is crucial in metal cutting as the edge geometry significantly influences both the material removal process and tool life. However, an analytical model that can physically describe the cutting edge preparation process has not yet been established. Taking the wet abrasive jet machining (WAJM) method as an example, the following questions always remain: Why does WAJM always form a relatively rounded cutting edge? What is the relationship between the process parameters and cutting edge geometries? This study, for the first time, proposes an analytical model for WAJM-based cutting edge preparation that simulates the transition from a sharp edge to a honed one under various process parameters. The model is based on energy principles and impact trajectories, allowing the calculation of the machining ability of a single particle. By extending impact process from flat polishing to the machining process of a topographic surface, and by introducing micro-scale contact theory, the model can predict the formation process of honed edge. Extensive experiments on carbide and ceramic inserts have been done for a comprehensive validation. The maximum Euclidean distance Ed<sub>max</sub> between predicted and measured edge profile is within 1 μm. The average prediction error for cutting edge parameters (S<sub>γ</sub>, S<sub>α</sub> and K) are below 10 %. For the depth of machining layers on rake and flank faces (D<sub>r</sub> and D<sub>f</sub>), errors are below 15 %. Building upon this foundation, the study elucidates the influence of the traverse speed and jet angle on the geometry of the cutting edge. The established model interprets the abrasive impact and cutting edge formation mechanisms of WAJM-based cutting edge preparation process, offering effective guidance for tool manufacturers to precisely control the cutting edge geometry.</p>}},
author = {{Yang, Yan and Weng, Jian and Xu, Dongdong and Zhou, Jinming and M'Saoubi, Rachid and Zhuang, Kejia}},
issn = {{1526-6125}},
keywords = {{Analytical model; Cutting edge preparation; Overlapping impact; Wet abrasive jet machining}},
language = {{eng}},
pages = {{1275--1294}},
publisher = {{Elsevier}},
series = {{Journal of Manufacturing Processes}},
title = {{Modeling cutting edge honing process in wet abrasive jet machining}},
url = {{http://dx.doi.org/10.1016/j.jmapro.2025.08.071}},
doi = {{10.1016/j.jmapro.2025.08.071}},
volume = {{152}},
year = {{2025}},
}