Axial-compliant tools for adaptive chamfering of sharp-edges: Characterisation and modelling

This paper proposes a new predictive model for chamfer size calculation in axially spring-compensated 90° conical tools. The goal is to predict cutting forces in the absence of compliance and then apply them to the axial-compliant case. The main contribution of this paper is the inclusion of the spring kinematics in the mechanistic model to obtain the chamfer size as an output of the process conditions. Thus, this model enables the control of the chamfer size, within tolerances, setting the process conditions according to desired result. The effectiveness of this model is verified through experimental test on representative test parts.