Cutting Edge Honing With Non-Newtonian Fluids

Abstract

Cutting tool edges are honed to an edge radius of about 15-30 micrometers for enhancing tool performance. During honing, defects left by prior manufacturing processes such as grinding and pressing are removed to achieve a higher quality edge. Recently, researchers have shown that tailoring the edge microgeometry to comprise an asymmetric shape and/or a gradient edge microgeometry is beneficial. Conventional edge honing processes such as brush honing and abrasive micro-blasting are limited in terms of reliably generating such geometries in a productive manner. To this end, this research explored the application of non-Newtonian aqueous suspensions of cornstarch and abrasives, for the edge honing of cutting tools. This thesis details the science, technology, characteristics and capabilities of this innovative process.