On the effects of tool nose radius in alleviating parasitic mechanisms for cutting of aluminum alloy

Despite extensive research and process advancements, parasitic mechanisms such as chatter, excessive tool wear, and energy dissipation continue to undermine the efficiency and sustainability of machining processes. These mechanisms, coupled with increased cutting forces and diminished surface quality, present persistent challenges. This study focuses on the cutting tool nose radius – a critical geometric parameter – as a lever to mitigate these issues. Through a systematic series of experiments on the machining of Al 6061-T6, the influence of tool nose radius on key machining parameters, including cutting forces, specific energy, chatter stability, tool wear, and surface finish, was investigated. Qualitative and quantitative analyses revealed that larger nose radii improve surface finish and reduce tool wear by distributing cutting forces more effectively, while smaller radii enhance chatter stability and reduce specific energy and chip load. However, the trade-offs between these parameters underscore the complex interplay of geometric and process variables. The findings provide a nuanced understanding of the role of nose radius in machining, identifying trends that align with theoretical principles of cutting mechanics and stability. An optimal nose radius was identified that balances improved cutting performance with compromises in wear and surface quality, paving the way for frugal, low-cost solutions to enhance machining efficiency and sustainability. This work not only advances the theoretical framework of cutting mechanics but also offers practical insights for developing sustainable manufacturing processes through informed tool design and selection.