Abstract
The turning process is the main machining task in brake disc production, and the PCBN tool is the most suitable type of cutting tools in the machining of brake discs made of cast iron. The edge geometric optimization of the PCBN tool is the key factor to obtain a better tool performance. In this paper, the cutting simulation for the machining of cast iron with PCBN tool of grade HNMN120712 was established, which exhibits a simulation error lower than 10.8%. The optimal turning parameters were obtained by the equal material removal rate method. The edge geometric parameters were optimized in two stages: firstly, the optimal edge radius was obtained as 30 μm by the comprehensive normalization analysis of the cutting temperature and stress, and then, the chamfer width and angle were further optimized to 0.1 mm and 15°. At finally, the optimized PCBN tool was prepared and tested in the machining of brake discs; the results indicate that the designed tool exhibits an excellent tool performance with 3.4 times the tool life of the conventional tool.