Abstract

This article presents a study of the influence of cutting edge rounding on the wear of monolithic milling tools using the finite element method (FEM) and DEFORM 3D software. After manufacturing by grinding, monolithic milling tools have considerably sharp cutting edges that are prone to breakage and chipping. Industrial practice and cutting edge zone theory recommend edge preparation to create a defined cutting edge radius. The optimal radius value depends on the machined material, cutting conditions, and other factors, and remains unclear. This study investigates the influence of the cutting edge radius on tool wear using 3D FEM simulation with the Usui wear model, which is considered suitable for machining processes. Initial simulations with sharp cutting edges were performed to determine the sensitivity of wear predictions to the Usui model constants. Subsequently, different cutting edge radii were simulated under identical cutting conditions. The simulation results demonstrate the relationship between cutting edge radius and wear progression. The findings provide guidelines for selecting suitable cutting edge preparation parameters to minimize tool wear when milling with monolithic tools.