Effect of chamfer width and chamfer angle on tool wear in slot milling

Abstract The tool geometry is generally of great significance in metal cutting performance. response surface method was used to optimize chamfer achieve reliable and minimum wear slot milling. Models were developed for edge chipping, rake wear, flank wear. adequacy the models verified using analysis variance at a 95% confidence level. Each optimized individually, multiple responses simultaneously desirability function approach. Monte Carlo simulation applied tolerance analysis. All milling tests conducted dry conditions; width angle varied between 0.1 0.3 mm, 10 30°, respectively. Optimal minimizing chipping small angle. reached value with 0.18 mm 10° obtained composite model predicted good strength overall when wide Thermal cracks observed on tools. They edges finest least negative but more significant greater chamfer. A also resulted insufficient chip evacuation. results show how affects tool’s reliability may help manufacturers minimize cost downtime.