Steady tool wear and its influence on tool geometry in ultra-precision fly cutting of CuZn30

  • Guoqing Zhang
  • Suet To
  • Xiaoyu WuEmail author
  • Yan Lou


In ultra-precision fly cutting (UPFC), steady tool wear progresses gradually when cutting ductile materials. The steady wear of diamond tools changes the tool geometry, and further affects the topography of the machined surface. In this study, a theoretical and experimental investigation was conducted on the forms of steady tool wear and their influence on the tool geometry in UPFC. The features of steady tool wear in UPFC were investigated, the displacement of the cutting edge under the effects of tool flank wear was modeled, and factors affecting the cutting edge roundness were investigated. The study results indicate the following: (1) the features of steady tool wear in UPFC include crater wear on the rake face, smooth and flat wear on the cutting edge, and flank wear on the tool clearance face. (2) A smooth wear-land on the cutting edge changes the top rake of the cutting tools, whereas flank wear on the tool clearance face affects the clearance angle and roundness of the cutting edge. (3) The maximum width of the tool material loss zone, the nose radius of the original fresh cutting edge, and the arc angle of the wear-land have a certain influence on the nose radius of the worn cutting edge. The results of this study will provide deep insight into steady tool wear and its influence on the tool geometry, which can potentially be used to predict or evaluate the finish of a machined surface under tool steady wear.


Ultra-precision fly cutting Tool wear Tool geometry Cutting edge roundness 


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Funding information

This work was supported by the National Natural Science Foundation of China under Grant (51505297, 51575360 and 51675347); the Natural Science Foundation of Guangdong Province under Grant (2017A030313295 and 2014A030310261); the Shenzhen Science and Technology Program under Grant (JCYJ20160422170026058); and the Shenzhen Peacock Technology Innovation Project under Grant (KQJSCX20170727101318462).


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Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2018

Authors and Affiliations

  1. 1.Guangdong Provincial Key Laboratory of Micro/Nano Optomechatronics Engineering, College of Mechatronics and Control EngineeringShenzhen UniversityShenzhenChina
  2. 2.State Key Laboratory of Ultra-Precision Machining Technology, Department of Industrial and Systems EngineeringThe Hong Kong Polytechnic UniversityHong KongChina

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