Effect of Cutting Edge Preparation by Drag Finishing on the Tool Wear in Milling of Steel

Effect of Cutting Edge Preparation by Drag Finishing on the Tool Wear in Milling of Steel | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Effect of Cutting Edge Preparation by Drag Finishing on the Tool Wear in Milling of Steel Rodrigo Panosso Zeilmann, Luccas Augusto Pedrassani Delgado, Jean Lucca Nunes Subtil This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7574233/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 23 Feb, 2026 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted 4 You are reading this latest preprint version Abstract Cutting edge preparation by drag finishing is used to refine microgeometry and extend tool life, especially when machining difficult-to-cut materials. This study investigates the influence of different abrasive media in drag finishing on the cutting edge microgeometry and wear behavior of cemented carbide end mills during milling of two steels, AISI P20 and SAE 4140. The objective is to understand the effects of abrasive media and contribute to the development of alternative solutions. The results showed that, in general, tools with edge preparation exhibit longer tool life compared to unprepared (sharpened) tools. The alternative ZR medium proposed in this work proved to be a viable option for the drag finishing process. milling drag finishing cutting edge tool wear abrasive media AISI P20 SAE 4140 Figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 1. Introduction Milling is a widely used machining process in the industry, mainly due to its kinematics, which allow for versatility and the ability to produce different surface finishes on the workpiece. In the context of mold production, this process is particularly widespread. In such instances, materials characterized by low machinability are frequently utilized, resulting in machining challenges that are often associated with rapid tool wear (Poulachon et al., 2004 ). Therefore, research exploring methods to enhance the tool life of milling cutters is crucial, as it can result in substantial cost and time savings. During the manufacturing of a cutting tool, the grinding process typically results in a sharp cutting edge. The presence of microdefects, such as burrs, micro-cracks, chipping, and irregularities, can lead to an unreliable tool behavior. The cutting edge condition is a key factor during machining operations, as high temperatures and mechanical stresses are experienced. Therefore, the cutting edge preparation process generates a well-defined microgeometry, increasing the stability of the wedge and the cutting edge itself. Manufacturing microdefects are reduced or eliminated and the surface of the edge is improved. The main goal is to increase the cutting tool life, enhancing the process reliability (Denkena and Biermann, 2014 ). In addition to the defects that the cutting edge may exhibit after tool manufacturing, the milling process is distinct from the drilling and turning processes in one fundamental aspect: the cutting is interrupted. In milling, the cutting edges are not continuously engaged with the workpiece during the rotation. This leads to alternating thermal and mechanical stresses on the tool material, which can accelerate wear on the cutting edge. Consequently, modifications to the cutting edge geometry can be implemented to enhance cutting stability (Klocke, 2018 ). A proper cutting tool characterization is fundamental to define its impact on the machining process. In the past, the only parameter used to characterize the cutting edge was the edge radius \(\:{r}_{\beta\:}\) . However, this is insufficient to provide precise information about the edge microgeometry. Denkena in 2002 defined parameters \(\:{S}_{\gamma\:}\) , \(\:{S}_{\alpha\:}\) , \(\:\varDelta\:r\) , \(\:\phi\:\) , and the K form factor, in addition to the \(\:{r}_{\beta\:}\) , seen on Fig. 1 (Denkena, 2005). Some authors as Rodriguez (2009) and Wyen (2012) proposed a different approach to give a detailed characterization method, but the complexity and difficulties to implementation made the factor form K the best alternative to provide reliable information about the cutting edge profile, used by the majority of the literature and industry (Denkena and Biermann, 2014 ). Over the years, a number of cutting edge preparation processes have been developed. Among these processes, drag finishing involves immersing and moving the cutting tool in an abrasive media, where friction with the grains smooths the surfaces and modifies the cutting edge microgeometry (Tikal, 2009 ). This media is generally composed of 3 materials: A filler material that transports the abrasive and contains larger grains.; an abrasive material with a smaller grain size that is responsible for the abrasive action of the media; and a high-viscosity adhesive oil that has the function of adhering the grains of the filler material to the grains of the abrasive material. The abrasive media are usually silicon carbide, ceramic, quartz, or plastic bonded abrasive particles (Wang et al., 2020 ). The relative motion between tool and abrasive removes material from the surface, with particle size and composition being key to the removal rate (Tikal, 2009 ). Several studies have evaluated the impact of edge treatment on the milling process. One of them is Bouzakis et al. ( 2014 ), who evaluated different edge treatment methods on milling inserts for various materials. The study showed that cutting edge preparation can improve tool performance, with gains of up to 93% compared to untreated inserts, depending on the material machined and the technique used. In the study by Uhlmann et al. ( 2016 ), the authors tested micro-mills with and without edge treatment. The work revealed that the microgeometry of the cutting edge positively influences the cutting forces, tool wear and surface roughness of the machined part. Comparative studies have also explored the performance of different edge preparation techniques. Zeilmann et al. ( 2018 ) compared drag finishing and brushing with no edge preparation, focusing on surface quality in milling AISI P20. The authors concluded that both cutting edge preparation methods were effective in reducing the surface roughness of the workpiece, being that with drag finishing producing the most homogeneous finish. Hronek et al. ( 2018 ) compared drag finishing using HSC 1/300 and QZ 1–3W media to water jet preparation, when machining Inconel 718. By testing cutting edge radii of 15 µm, 20 µm, and 25 µm, they found that drag finishing consistently offered better tool durability and surface finish, with the best performance at a 15 µm radius using HSC 1/300 media. Although research on drag finishing and its application to cutting tools has been increasing, studies specifically addressing the role and characteristics of abrasive media remain limited, despite abrasive media being one of the key variables in the process. Among the main studies are those by Uhlmann et al. ( 2014 ), Malkorra et al. ( 2021 ), Lv et al. ( 2021 )d rez-Salinas et al. (2022). In all cases, the abrasive media had a significant impact on the microgeometry and surface condition of the cutting edge. This new scientific contribution from this work is the evaluation of the effects of two commercial and one alternative media by analyzing changes in cutting edge geometry through detailed characterization techniques and this effect under the wear and behavior during the milling of AISI P20 and SAE 4140 steels. 2. Materials and methods In this section the experimental methodologies, equipment, tools, and materials used are presented to support the analysis, through an experimental plan, seen in Fig. 2. Regarding the input data, the machining conditions for the experiment were maintained fixed, while the workpiece material consisted of two different types of steel. Also, in order to comprehend the impact of the drag finish, four different microgeometries of cemented end mills were generated using three different abrasive media. This directly influences the output data that was evaluated. Therefore, since the objective of this study was to analyze the wear of these cutting tools, a set of analysis was performed to reach this goal. 2.1 Workpiece These experimental tests were performed using two types of workpiece material with distinct hardness. The first workpiece utilized was an AISI P20 steel (W.Nr 1.2311; DIN X40CrMnMo7), a material frequently employed in the fabrication of plastic injection molds. It has undergone a hardening process, resulting in a 36 ± 2 HRC hardness. Additionally, its chemical composition essentially contains 0.409 wt% C, 2.033 wt% Cr, 0.108 wt% Co, 0.119 wt% Cu, 0.716 wt% Ni, 1.462 wt% Mn, 0.201 wt% Mo, 0.022 wt% P, 0.377 wt% Si, 0.384 wt% S and Fe as balance. The workpiece size was 252 mm (l), 80 mm (w), 60 mm (h). The second material utilized was the SAE 4140 (DIN 42CrMo4), which had a measured hardness of 20 ± 2 HRC. The chemical composition is 0.417 wt% C, 1,02 wt% Cr, 0.140 wt% Cu, 0.110 wt% Ni, 0.860 wt% Mn, 0.180 wt% Mo, 0.011 wt% P, 0.005 wt% S, 0.240 wt% Si and Fe as balance. The workpiece size is 200 mm (l), 80 mm (w) and 60 mm (h). 2.2 Machining conditions and equipment For the machining tests, the strategy adopted was to use down milling without cutting fluid (dry). The cutting speed (v c ) and feed per tooth (f z ) were set at 180 m/min and 0.05 mm/tooth, respectively, while the axial (a p ) and radial (a e ) depths of cut were 0.5 mm and 0.2 mm, respectively. The ratio length/diameter was three. The cutting parameters were fixed in all tests. These cutting conditions were defined in pre-tests. Figure 3 illustrates the milling process and the conditions used. Every 5040 mm of linear cutting, the tool was removed from the machine to inspect and measure the tool wear. The tool life criterion established in this experiment is \(\:{VB}_{max}\) = 0.2 mm or noticeable cutting edge chipping. End of test criterion was set to a linear distance of 30 m for the machining of AISI P20 and 50 m for machining the SAE 4140 steel. Two cutting tools for each microgeometry condition were used, to ensure a reliable result. The CNC machine utilized was a Hartford LG-500, with a power of 12 kW and maximum spindle speed of 10,000 rpm. The end mills were fixed using a hydraulic expansion toolholder, manufactured by Schunk, model TENDO E compact. Proceeding the characterization, for the macroscopic view, an Entex TNE-10B stereoscope was used, in conjunction with a CCD camera to capture images of the tools. For a better understanding of the microgeometry of the end mills, a Scanning Electron Microscopy (SEM), made by Tescan model Mira 3 was utilized to characterize the new and used tools. To verify the cutting edge parameters and microgeometry, an optical 3D measurement device made by Alicona, model Edge Master, was utilized. 2.3 Cutting Tool The end mills used on the machining tests were developed exclusively by the tests and manufactured by Secta Tools. Figure 4 shows the tool, with information about the macrogeometry. For the experiment, 6 mm diameter tools were used, with four cutting edges and without coating. The substrate was cemented carbide (WC), ISO K40 grade with 10% Co, manufactured by the Ceratizit Group, with ISO h6 tolerance. The material characteristics include an average WC grain size between 0.5 and 0.8 µm (submicron class) and a hardness of 1600 HV30. 2.4 Cutting edge treatment For the cutting edge preparation, the tools were treated by a drag finish process. To analyze the influence of the three abrasive media: HSC 1/300 (1/300), H4/400 (4/400) and a non-commercial media proposed by the authors called Zirconite (ZR). A sharpened tool (SH) was used as the reference condition. OTEC Präzisionsfinish GmbH supplied the HSC 1/300 and H 4/400 abrasive media. HSC 1/300 consists of a mixture containing 30% silicon carbide (SiC) with a grain size of ≈ 200 µm and 70% walnut shell granules with grain sizes between 800 and 1300 µm. H 4/400, on the other hand, is composed of walnut shell granules with grain sizes between 400 and 800 µm and a polishing paste containing diamond particles (Uhlmann, 2014; Uhlmann, 2016). The edge treatment with HSC 1/300 and H 4/400 was performed using an OTEC SF-3 machine. The non-commercial media proposed by research group consists mainly of peanut shell granules (with a grain diameter between 841 µm and 1410 µm) and Zirconite (ZrSi \(\:{O}_{4}\) ) (with a grain diameter of between 149 µm and 210 µm). The proportions of these two components in the abrasive media are 70% and 30%, respectively. As illustrated in Fig. 5, the procedure for obtaining the media and its components is as follows. Peanut shells were separated from the grain and dried in the oven, to eliminate the moisture. A knife mill was used to grind the shells in a constant rotation. A vibrating sieve was used to sift the shell in the desired particle size, between mesh 14 and 20. The result was a controlled particle size diameter (0,8 to 1,41 mm). On the other hand, Zirconite was obtained in various particle sizes, requiring the use of a vibration sieve in order to control the particle sizes between the sieves of mesh 65 and 100. Particle size was between 150 and 210 µm. The mixing process mainly consists in adding 2,00 ml of OTEC adhesive oil in a container with the peanut shells, during 20 minutes. Zirconite was slowly added to the mixture over a period of 10 minutes, concluding the process. The cutting edge preparation using ZR abrasive media was carried out with some characteristics that distinguished it from the approach employed by OTEC. Due to the size difference between the industrial container used at the OTEC factory and the laboratory setup adopted in this work, the drag finishing parameters for ZR were specifically adjusted to match the tangential contact velocity applied with the 1/300 and 4/400 abrasive media. Table 1 shows the specified parameters done in the different media. Table 1 Drag finish process parameters Abrasive Media Type of process Time of Process (sec) Direction Rotation of the Tool (rpm) 1/300 Dry Polishing 30 Clockwise 40 4/400 Dry Polishing 120 Clockwise 40 ZR Wet Polishing 600 Clockwise 265 The drag finishing parameters have a direct influence on the cutting edge radius produced. Risse ( 2006 ) and Vozár et al. (2020) tested different parameter combinations to compare the influence of each parameter in the cutting edge radius. In their results, the rotation of the tool was the most important parameter, since it determines the rate of material removal. The processing time is a variable that makes an important contribution to the rounding of the cutting edge. Uhlmann et al. ( 2014 ) investigated the material removal as a function of processing time using different types of media. They observed faster material removal with the HSC 1/300 medium compared to the H 4/400 medium. Therefore, in this experiment, combinations of parameters were used with the aim of achieving a comparable cutting edge radius. 3. Results The following results show the correlation between edge preparation by the drag process, using different abrasive media with the wear of end mills. Therefore, machining tests were carried out, using a standard tool as a reference, followed by tools with the prepared cutting edge. Wear was measured progressively and an end-of-life criterion was established and the results discussed. 3.1 Cutting Tool Characterization An important way to obtain reliable information about the impact of the cutting edge preparation on the tool microgeometry is through a characterization. The infinity focus system of the Alicona Edge Master Series was used to measure the microtopography and contour of the cutting edge, providing numerical results. Table 2 contains the characterization parameters from the cutting edge for the microgeometries conditions. Table 2 Cutting edge characterization parameters Edge Condition \(\:{r}_{\beta\:}\) (µm) Sα (µm) Sγ (µm) K (-) Δr (µm) SH 3,904 15.981 2.196 0.137 3.339 1/300 7.653 11.626 11.047 0.950 6.017 4/400 8.287 14.697 12.645 0.860 6.408 The tools were treated by OTEC Präzisionsfinish GmbH in Germany using the HSC 1/300 and H 4/400 abrasive media. A complete characterization was carried out on the tools in both sharpened and treated conditions. However, the edge preparation of the tools with ZR media was performed by the research group at the University of Caxias do Sul, and a more detailed characterization was not possible. The SEM images (Fig. 6) show that the cutting edge topography in the ZR condition is similar to the standard condition. The hypothesis is that the cutting edge rounding radius \(\:{r}_{\beta\:}\) in the ZR condition is greater than that of the standard condition but smaller than in the other treated conditions. Sharpened tool (SH) is the untreated edge and has been considered the ground tool for this experiment. During tool manufacturing, the meeting of the abrasive grinding wheels generates a sharp cutting edge, and the properties presented in abrasive grains can directly impact the surface finishing (Denkena and Biermann, 2014 ). Results show the SH tool has the smallest cutting edge radius \(\:{r}_{\beta\:}\) . The value of K factor was closer to zero, indicating that the cutting edge contour has a waterfall geometry. Conditions as presented show an irregular surface all along the cutting edge, therefore, the largest deviation of the four conditions. On the other hand, the drag finishing process using HSC 1/300 and H 4/400 media increased the edge radius by 96% and 112%, respectively, compared to the SH tool. The dispersion of the radius values along the section measured is reduced for the HSC 1/300 and H 4/400 tools. Authors such as Uhlmann et al. ( 2014 ) and Zeilmann et al. ( 2018 ) also reported an increase in the cutting edge radius and a reduction in tool surface roughness. This behavior is expected in tools that were prepared, since the edge material is removed within the process, leveling the surface. Figure 6 presents the characterization performed using a Tescan Mira 3 SEM. The image provides a detailed image of the flank face and rake face of the tools before the experimental tests. It is possible to see that the unprepared tool (SH) has several grinding marks on the flank face and rake face and edge chipping. Regarding the 1/300 media, improvements can be seen in the surface of the edge, exhibiting a significant reduction in defects and grinding marks on the face and flank of the tools. Also, the micro-chipping previously present was eliminated for the traditionally verified viewing. The removal of material from the surface of the edge ends up making changes to the topography of the edge. Peaks and valleys that were previously protruding have been reduced or leveled out, affecting the surface roughness of the sample. Consequently, this results in a homogeneous roundness along the edge. As indicated in the works of D Lv et al. (2022) and Bordin and Zeilmann ( 2014 ), the utilization of the same abrasive media for edge treatment led to similar results. For the 4/400 tool, it is noticeable that the majority of the defects and marks are eliminated. This is the desired effect of edge preparation, and depending on the media utilized, the surface of the tool responds differently. A finer particle media requires more process time to obtain the same rounding as a rougher media, but the benefit is a refinement of the surface. H 4/400 media have diamond abrasive in its composition, due to a low particle granulometry, rugosity can be lowered when applied this media The ZR tool shows a poor surface quality compared to the prepared end mills, and it is still possible to see the marks generated by the grinding process on both the rake face and the flank face. A serrated texture can be observed near the cutting edge, as on the SH tool, which is not seen on the other treated tools. This phenomenon can be attributed to the resulting Zirconite and peanut shell size particles, which are larger than expected and are not evenly distributed. It has been established that variations in the process may have a direct impact on the abrasive potential of the media, resulting in a less refined surface when compared to that produced by the H 4/400 and HSC 1/300 media. It is further corroborated by the fact that the tangential speed of the ZR tool was identical to that employed in H 1/300 and H 4/400 media, and the process time was 400% longer. ZR only achieved a small improvement in surface quality compared to the SH tool. 3.2 Tool Wear To address the effect on the wear made by the edge preparation process, it is appropriate to perform a tool behavior curve. This demonstrates how the tool responded to a specific cutting length, thereby making it possible to evaluate the influence of edge treatment. 3.2.1 AISI P20 The first analyzed material was the AISI P20 mold steel. In Fig. 7, it is possible to see the tools in their new state, and after reaching the established end-of-life criterion of 0.20 mm (VBmax). All the new tools had no macro-defects such as burrs or chipping that would interfere with the tests. The tools were monitored and measured according to the specified interval, in order to properly control the wear behavior and types of wear present on the tools. During the experimental tests, the cutting tools primarily showed the abrasive wear mechanism. In general, flank wear was regular among the four conditions. Abrasion, identified by scoring marks on the cutting edge, naturally occurs under cutting friction contact, which is typical when machining this type of material (Wu et al., 2020). Minor chipping of the cutting edge was mainly observed on the SH and ZR tools. This can be attributed to the cutting edge radius, since a smaller radius, as encountered in both ZR and SH conditions, provides lower resistance to fracture, leading to the incidence of chipping throughout the cut. In addition, this is intensified by the fact that milling is an interrupted cutting process, with tool entry and exit impacts that subject it to cyclic thermal and mechanical loads (Hopkins et al., 2024). An SEM image of the SH and 1/300 tool when reaching the end of the test criterion (30 linear meters) can be seen in Fig. 8. The adhesion mechanism, although it was difficult to identify in the optical microscope, was evident in the SEM. Adhesion occurs under high temperatures and compressive stress, and severe adhesive wear usually appears before the tool reaches its normal wear life (Liu et al., 2018 ). In all microgeometry conditions the same mechanisms and types of wear were observed. For AISI P20 steel, the wear behavior of the tools is shown in Fig. 9. The H 4/400 tool exhibited the least flank wear, from the beginning of the cut to the end-of-life criterion, when compared to the other microgeometry conditions. The SH, HSC 1/300, and ZR tools showed similar tool wear up to 10 meters. After this cutting length, the other treated tools followed practically the same wear level during the test. The sharpened tool, on the other hand, resulted in the highest flank wear among the four conditions. During the manufacturing of the cutting tool, the sharpening process generates grinding marks. Depending on the orientation of these marks, they can negatively impact the tool life, as the chip follows against the marks, thereby raising both the friction and the local temperature (Denkena et al., 2013 ). Furthermore, the sharpening promotes typical cutting edge defects such as micro-burrs, micro-chipping and an overall poor surface quality. This factor influences the stability of the cutting edge and reliability of the process, reducing the tool life and leading to an uneven wear behavior (Rech, 2005). Depending on the form factor K = \(\:\frac{S\gamma\:}{S\alpha\:}\) , the primary wear mechanism can be different. For tools with an asymmetrical radius (K >1), there is a tendency to increase tool life. Higher values of \(\:S\alpha\:\) results in a higher flank wear (Denkena 2011; Denkena 2012). Since the SH condition has a low factor form K = 0.137, it was observed that this condition had the most flank wear among the tools. Symmetrical cutting edges (K = 1) provide a higher mechanical stability, leading to a low occurrence of chipping. Denkena et al, 2009 performed an experiment using an uncoated cemented carbide milling tool with the edge preparation and form factor K = 1, the results show an enhanced in the tool’s life in 70% when machining Ti6Al4V. Thus, the results obtained for the cutting edge radius and the form factor K indicate values close to 1 and, therefore, caused the improvement in the tool life for the drag finish with HSC 1/300 and H 4/400 media. Zirconite media also reduce the flank wear, but with no information on the form factor K value. 3.2.2 SAE 4140 The same procedure performed in the AISI P20 material was executed for the SAE 4140. Figure 10 illustrates the tools when reaching the tool life criterion. Since this material was not subjected to a hardening treatment, its hardness is lower in comparison to AISI P20. Consequently, the mechanical stresses on the cutting edge did not result in any defects, such as chipping or breakage. In addition, the identified wear mechanisms were abrasion and adhesion, which are consistent with the findings for AISI P20. In Fig. 11. is possible to see the wear behavior of the cutting tools when machining SAE 4140 steel. The wear behavior of the four microgeometry conditions remained constant and similar up to the 20 linear cutting length. After 20 meters, the H 4/400 tool showed high wear compared to the other tools, reaching the end-of-life criterion with a shorter linear cutting length. From this point onwards, the deviation of the values was the highest among all the conditions, which indicates a discrepancy between the wear of the individual's cutting edge. This can be attributed to an increased cutting edge radius, since the H 4/400 have a higher radius. As the radius of the tool increases, the ploughing effect occurs, in which material is trapped in the cutting edge of the tool and is pushed towards the tool flank, not effectively cutting the material, but deforming it. The cutting forces rise, as well as the residual stress. negatively affect the tool's wear behavior. For the HSC 1/300 and SH tools, similar wear behavior throughout the cut, reaching the tool life criterion in almost the same cutting length, favoring the SH condition. Both conditions have a lower cutting edge radius than the H 4/400 tool. ZR media resulted in the least tool wear among all conditions. Nardy et al ( 2024 ) performed a hard turning test in a SAE 4140 workpiece, but in the hardened condition, exhibiting around 50 HRC. The main comparison was the different approach to factor form K. In the results, the factor form K = 1 and K = 2 of the grinded edge prepared inserts showed the least tool wear, compared to the sharp unprepared insert. In this case, the severity of the process combined with a higher hardened material favors the higher rounding, since the contact area is increased, the cutting pressure is reduced, enhancing the tool life. On the other hand, in the work proposed by Bouzakis 2014, using the equivalent material (42CrMo4) and several preparation methods, including drag finishing, results shows that smaller cutting edge radius, without preparation, resulted in a better tool life. The elevated temperatures generated by the rounded cutting edge, typically higher than those of tools without edge preparation, can alter the workpiece microstructure, potentially affecting its machinability. These results highlight that the material condition can significantly influence tool life. SAE 4140 steel is widely used in industrial applications due to its good hardenability (Irsel et al., 2022). Also, size of the radius in which the tools performance is higher depends on a number of factors such as the workpiece material and its mechanical properties, cutting parameters and tools macrogeometry (Tikal, 2009 ; Denkena and Biermann, 2014 ). 3.2.3 Cutting Length For both workpiece materials, the cutting tool life is presented in Fig. 12. When machining AISI P20 the SH tool resulted in the lowest cutting length, completing 16.2 meters when reaching the maximum flank wear. The smaller cutting edge radius and the surface defects generated from the grinding process negatively affected the performance. For the ZR and HSC 1/300 tools, cutting edge preparation increased the tool's performance, resulting in a 5% improvement in the total number of linear meters machined. The tool treated with the H 4/400 media showed a 19% increased tool life than the SH. The dispersion of the values was adequate between the four conditions tested. These results are in agreement with other authors that machining materials with similar hardness. Barbosa et al. ( 2021 ), carried out a test using an end mill with and without cutting edge preparation on a similar material VP20TS, and described a reduction in wear of the treated tool and an improvement in the machined surface. To SAE 4140 steel, the H 4/400 media tool machined almost five linear meters less than SH tool, which reduced the tool life by 16%. These two microgeometry conditions resulted in a low deviation, pointing to a suitable performance. HSC 1/300 media resulted in a 1% reduction in the tool life. Meanwhile, the drag finishing process using Zirconite abrasive media resulted in an increase in the end mill life by almost 10%. Wang et al. ( 2020 ) reported a 168% improvement in tool life when machining AISI 4140 steel in orthogonal turning using drag-finished inserts. However, in two microgeometries conditions (ZR and 1/300) a large deviation of the values was observed. Some factors may have influenced this discrepancy in the results. In the case of the drag finishing process, the operations were carried out in a strictly similar manner for all tools, respecting the selected process parameters. A possible variation can be attributed to the workpiece. Since it varied with each tool, some differences between workpiece materials are expected, but not enough to generate this abnormal discrepancy in machined length. The most plausible hypothesis could be some variation in the tool manufacturing process. During the grinding process, the abrasive wheels that are used to determine the macrogeometry of the tool may be interfered with, resulting in a cutting tool that is out of specification. This has a direct influence on the cutting mechanics and consequently on wear behavior. 4. Conclusions Edge preparation constitutes a critical stage in the manufacturing of cutting tools. Among the available techniques, drag finishing is widely recognized for its effectiveness in promoting cutting-edge rounding. In this study, a comprehensive investigation was conducted into the use of different abrasive media, with the aim of elucidating their direct influence on tool performance and machining behavior. Thus, the following main findings were made: Significant improvements in tool microgeometry and surface finish were observed following edge preparation. Defects previously identified in the SH tool were successfully eliminated. Among the tested media, H 4/400 demonstrated the highest effectiveness in removing such defects and homogenizing the microtopography. In general, tools subjected to edge preparation exhibited superior tool life compared with the sharpened tool. Across all experimental conditions, the types and mechanisms of wear remained consistent. All abrasive media applied in the drag finishing process enhanced cutting tool life during the machining of AISI P20 steel. Specifically, the HSC 1/300 and Zirconite media extended tool life by approximately 6%, whereas the H 4/400 medium achieved an improvement of nearly 20%. With regard to SAE 4140 steel, the sharpened tool (SH) proved to be the most reliable, as indicated by its lower variability in tool life measurements. In contrast, the H 4/400 medium resulted in a reduction of 16% in tool life, while HSC 1/300 led to a 1% reduction. The Zirconite (ZR) medium, however, produced an increase of 10% in cutting length, albeit with higher deviations in results, similarly observed for both HSC 1/300 and Zirconite media. The alternative Zirconite (ZR) medium, proposed by the research group, was shown to be a promising candidate for application in the drag finishing process. Its influence on tool life was favorable, as evidenced by improvements in comparison with the SH tool across both workpiece materials. Nevertheless, the surface finish of the cutting edge was inferior to that obtained with OTEC media, as residual defects originating from the manufacturing process persisted. Future refinement of the abrasive medium is therefore recommended to further enhance its effectiveness. Declarations Competing interests The authors declare no competing interests. Funding This work was supported by Luccas A P Delgado, Jean L N Subtil and Rodrigo P Zeilmann with support from OTEC and University of Caxias do Sul, Capes, and CNPq. Authors’ Contribution All authors contributed to the study conception and design. Acknowledgements The authors would like to thank the University of Caxias do Sul for providing the facilities to carry out the experiment, OTEC Präzisionsfinish GmbH (Germany), for their partnership and preparation of the drag finishing tools, Secta Tools for providing the tools, CNPQ and CAPES for their scholarship and support. References Poulachon G, Bandyopadhyay BP, Jawahir IS, Pheulpin S, Seguin E (2004) Wear behavior of CBN tools while turning various hardened steels. Wear 56:302–310. https://doi.org/10.1016/S0043-1648(03)00414-9 Denkena B, Biermann D (2014) Cutting edge geometries. CIRP Annals - Manufacturing Technology 63: 631–653. http://dx.doi.org/10.1016/j.cirp.2014.05.009. Klocke F (2018) Fertigungsverfahren 1: Zerspanung mit geometrisch bestimmter schneide. 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Procedia CIRP 46: 352–355. https://doi.org/10.1016/j.procir.2016.04.004 Zeilmann R, Ost C, Fontanive F (2018) Characterization of edge preparation processes and the impact on surface integrity after milling of AISI P20 steel. Journal of the Brazilian Society of Mechanical Sciences and Engineering 40: 421. https://doi.org/10.1007/s40430-018-1338-7(0123456789().,-volV)(0123456789().,-volV) Hronek O, Zetek M, Bakša T, Adámek P (2018) Influences of Cutting Edge Microgeometry on Durability when Milling ISO S Material. Manufacturing Technology 18: 394-399. https://doi.org/10.21062/ujep/111.2018/a/1213-2489/MT/18/3/394. Uhlmann E, Oberschmidt, Kuche Y, Löwenstein A (2014) Cutting Edge Preparation of Micro Milling Tools. Procedia CIRP 14: 349–354. https://doi.org/10.1016/j.procir.2014.03.083 Malkorra I, Souli H, Salvatore F, Arrazola P, Rech J, Cici M, Mathis A, Rolet J (2021) Modeling of drag finishing—Influence of abrasive media shape. Journal of Manufacturing and Materials Processing 5, 41. https://doi.org/10.3390/jmmp5020041. Lv D, Wang Y, Yu X, Chen H, Gao Y (2021) Analysis of abrasives on cutting edge preparation by drag finishing. International Journal of Advanced Manufacturing Technology 119: 3583–3594, 2022. https://doi.org/10.1007/s00170-021-08623-w Pérez-Salinas C, del Olmo, LACALLE N (2022) Estimation of Drag Finishing Abrasive Effect for Cutting Edge Preparation in Broaching Tool. Materials 15. https://doi.org/10.3390/ma15155135 Risse K (2006) Einflüsse von Werkzeugdurchmesser und Schneidkantenverrundung beim Bohren mit Wendelbohrern in Stahl. Doctoral dissertation, RWTH Aachen University. Bordin F, Zeilmann R (2014) Effect of the cutting edge preparation on the surface integrity after dry drilling. Procedia CIRP 13: 103–107. http://dx.doi.org/10.1016/j.procir.2014.04.018 Holpkins C, Clarke T, Nguyen N, Yussefian N, Hosseini A (2024) On modelling the cutting forces and impact resistance of honed milling tools. Transactions of the Canadian Society for Mechanical Engineering 48: 53–67. https://doi.org/10.1139/tcsme-2023-0066 Liu, G-J, Zhou Z-C, Qian X, Pang W-H, Li G-H, Tan G-Y (2018) Wear Mechanism of Cemented Carbide Tool in High Speed Milling of Stainless Steel. Chinese Journal of Mechanical Engineering. https://doi.org/10.1186/s10033-018-0298-2 Denkena B, Köhler J, Ventura C (2013) Customized cutting edge preparation by means of grinding. Precision Engineering 37: 590–598. http://dx.doi.org/10.1016/j.precisioneng.2013.01.004 Rech J, Yen Y-C, Schaff M, Hamdi H, Altan T, Bouzakis K (2005) Influence of cutting edge radius on the wear resistance of PM-HSS milling inserts. Wear 259: 1168–1176. https://doi.org/10.1016/j.wear.2005.02.072 Denkena B, Lucas A, Bassett E (2011) Effects of the cutting edge microgeometry on tool wear and its thermo-mechanical load. CIRP Annals - Manufacturing Technology 60: 73–76. https://doi.org/10.1016/j.cirp.2011.03.098 Denkena B, Köhler J, Rehe M (2012) Influence of the honed cutting edge on tool wear and surface integrity in slot milling of 42CrMo4 steel. Procedia CIRP 1: 190-195. https://doi.org/10.1016/j.procir.2012.04.033 Denkena B, De Leon L, K̈hler J (2009) Cutting edge preparation for cemented carbide milling tools. Advanced Materials Research 76–78: 597–602. https://doi.org/10.4028/www.scientific.net/AMR.76-78.597 Nardy M, Souza J, Santos S, Alves M, Ribeiro M, Antonialli A, Ventura C (2024) Surface finish and edge preparation of Al2O3 + MgO cutting inserts by grinding and their application in hard turning. The International Journal of Advanced Manufacturing Technology 134: 677-689. https://doi.org/10.1007/s00170-024-14172-9 İrsel G, Güzey B, Kara B (2022) Effect of heat-treatment temperature on the mechanical and microstructural properties of AISI 4140 steel. International Scientific Conference UNITECH 2022 Gabrovo 18-19: 93-100. https://doi.org/10.62853/BSUC2659 Barbosa M, Hassui A, De Oliveira P (2021) Effect of cutting parameters and cutting edge preparation on milling of VP20TS steel. International Journal of Advanced Manufacturing Technology 116: 2929–2942. https://doi.org/10.1007/s00170-021-07654-7 Cite Share Download PDF Status: Published Journal Publication published 23 Feb, 2026 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted Reviewers agreed at journal 28 Sep, 2025 Reviewers invited by journal 13 Sep, 2025 Editor assigned by journal 13 Sep, 2025 First submitted to journal 11 Sep, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. 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7","display":"","copyAsset":false,"role":"figure","size":507794,"visible":true,"origin":"","legend":"\u003cp\u003eOptical microscopic view tools when with VBmax = 0.20 mm, on milling of P20 steel\u003c/p\u003e","description":"","filename":"Fig.71.png","url":"https://assets-eu.researchsquare.com/files/rs-7574233/v1/2d5345f3c06fd03532d6502c.png"},{"id":91820829,"identity":"2a64537e-deab-466e-977f-4cd2e5bbf31d","added_by":"auto","created_at":"2025-09-22 07:21:32","extension":"png","order_by":8,"title":"Figure 8","display":"","copyAsset":false,"role":"figure","size":457435,"visible":true,"origin":"","legend":"\u003cp\u003eSEM view of the SH and HSC 1/300 tools during machining of P20 steel.\u003c/p\u003e","description":"","filename":"Fig.81.png","url":"https://assets-eu.researchsquare.com/files/rs-7574233/v1/42b6d93dc49cbb44eb93a8d2.png"},{"id":91820835,"identity":"1bd83805-cf1e-4d54-9cf2-fbc258ef9ae0","added_by":"auto","created_at":"2025-09-22 07:21:33","extension":"png","order_by":9,"title":"Figure 9","display":"","copyAsset":false,"role":"figure","size":33329,"visible":true,"origin":"","legend":"\u003cp\u003eTool wear behavior for P20 steel\u003c/p\u003e","description":"","filename":"Fig.91.png","url":"https://assets-eu.researchsquare.com/files/rs-7574233/v1/2664130ae3221b44c3d61498.png"},{"id":91820833,"identity":"31ac59d2-77e1-4274-8a36-1ab7f2ae11a1","added_by":"auto","created_at":"2025-09-22 07:21:32","extension":"png","order_by":10,"title":"Figure 10","display":"","copyAsset":false,"role":"figure","size":499759,"visible":true,"origin":"","legend":"\u003cp\u003eOptical microscopic view of tools with Vb = 0.2 mm, on AISI 4140 steel\u003c/p\u003e","description":"","filename":"Fig.101.png","url":"https://assets-eu.researchsquare.com/files/rs-7574233/v1/be330e545767475bc2828faa.png"},{"id":91820824,"identity":"743debef-74b9-4fea-90af-d45168829258","added_by":"auto","created_at":"2025-09-22 07:21:32","extension":"png","order_by":11,"title":"Figure 11","display":"","copyAsset":false,"role":"figure","size":40229,"visible":true,"origin":"","legend":"\u003cp\u003eTool wear behavior for the SAE 4140\u003c/p\u003e","description":"","filename":"Fig.111.png","url":"https://assets-eu.researchsquare.com/files/rs-7574233/v1/8474b32bbb51a1e6046b354a.png"},{"id":91820841,"identity":"b6091c43-c19e-43e7-a1c9-83ce30ff7ccd","added_by":"auto","created_at":"2025-09-22 07:21:33","extension":"png","order_by":12,"title":"Figure 12","display":"","copyAsset":false,"role":"figure","size":21111,"visible":true,"origin":"","legend":"\u003cp\u003eCutting Length for the AISI P20 and SAE 4140 to Vb = 0.2 mm\u003c/p\u003e","description":"","filename":"Fig.121.png","url":"https://assets-eu.researchsquare.com/files/rs-7574233/v1/f97f4e6470fe2bf8f31c5dec.png"},{"id":103766061,"identity":"6fb62631-1834-4f88-8841-49220061be7d","added_by":"auto","created_at":"2026-03-02 16:11:56","extension":"pdf","order_by":0,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":4688876,"visible":true,"origin":"","legend":"","description":"","filename":"manuscript.pdf","url":"https://assets-eu.researchsquare.com/files/rs-7574233/v1/971648ae-be22-418f-ba56-b1fce0aaff6d.pdf"}],"financialInterests":"","formattedTitle":"\u003cp\u003eEffect of Cutting Edge Preparation by Drag Finishing on the Tool Wear in Milling of Steel\u003c/p\u003e","fulltext":[{"header":"1. Introduction","content":"\u003cp\u003eMilling is a widely used machining process in the industry, mainly due to its kinematics, which allow for versatility and the ability to produce different surface finishes on the workpiece. In the context of mold production, this process is particularly widespread. In such instances, materials characterized by low machinability are frequently utilized, resulting in machining challenges that are often associated with rapid tool wear (Poulachon et al., \u003cspan citationid=\"CR1\" class=\"CitationRef\"\u003e2004\u003c/span\u003e). Therefore, research exploring methods to enhance the tool life of milling cutters is crucial, as it can result in substantial cost and time savings.\u003c/p\u003e\u003cp\u003eDuring the manufacturing of a cutting tool, the grinding process typically results in a sharp cutting edge. The presence of microdefects, such as burrs, micro-cracks, chipping, and irregularities, can lead to an unreliable tool behavior. The cutting edge condition is a key factor during machining operations, as high temperatures and mechanical stresses are experienced. Therefore, the cutting edge preparation process generates a well-defined microgeometry, increasing the stability of the wedge and the cutting edge itself. Manufacturing microdefects are reduced or eliminated and the surface of the edge is improved. The main goal is to increase the cutting tool life, enhancing the process reliability (Denkena and Biermann, \u003cspan citationid=\"CR2\" class=\"CitationRef\"\u003e2014\u003c/span\u003e).\u003c/p\u003e\u003cp\u003eIn addition to the defects that the cutting edge may exhibit after tool manufacturing, the milling process is distinct from the drilling and turning processes in one fundamental aspect: the cutting is interrupted. In milling, the cutting edges are not continuously engaged with the workpiece during the rotation. This leads to alternating thermal and mechanical stresses on the tool material, which can accelerate wear on the cutting edge. Consequently, modifications to the cutting edge geometry can be implemented to enhance cutting stability (Klocke, \u003cspan citationid=\"CR3\" class=\"CitationRef\"\u003e2018\u003c/span\u003e).\u003c/p\u003e\u003cp\u003eA proper cutting tool characterization is fundamental to define its impact on the machining process. In the past, the only parameter used to characterize the cutting edge was the edge radius \u003cspan class=\"InlineEquation\"\u003e\u003cspan class=\"mathinline\"\u003e\\(\\:{r}_{\\beta\\:}\\)\u003c/span\u003e\u003c/span\u003e. However, this is insufficient to provide precise information about the edge microgeometry. Denkena in 2002 defined parameters \u003cspan class=\"InlineEquation\"\u003e\u003cspan class=\"mathinline\"\u003e\\(\\:{S}_{\\gamma\\:}\\)\u003c/span\u003e\u003c/span\u003e, \u003cspan class=\"InlineEquation\"\u003e\u003cspan class=\"mathinline\"\u003e\\(\\:{S}_{\\alpha\\:}\\)\u003c/span\u003e\u003c/span\u003e, \u003cspan class=\"InlineEquation\"\u003e\u003cspan class=\"mathinline\"\u003e\\(\\:\\varDelta\\:r\\)\u003c/span\u003e\u003c/span\u003e, \u003cspan class=\"InlineEquation\"\u003e\u003cspan class=\"mathinline\"\u003e\\(\\:\\phi\\:\\)\u003c/span\u003e\u003c/span\u003e, and the K form factor, in addition to the \u003cspan class=\"InlineEquation\"\u003e\u003cspan class=\"mathinline\"\u003e\\(\\:{r}_{\\beta\\:}\\)\u003c/span\u003e\u003c/span\u003e, seen on Fig.\u0026nbsp;1 (Denkena, 2005). Some authors as Rodriguez (2009) and Wyen (2012) proposed a different approach to give a detailed characterization method, but the complexity and difficulties to implementation made the factor form K the best alternative to provide reliable information about the cutting edge profile, used by the majority of the literature and industry (Denkena and Biermann, \u003cspan citationid=\"CR2\" class=\"CitationRef\"\u003e2014\u003c/span\u003e).\u003c/p\u003e\u003cp\u003eOver the years, a number of cutting edge preparation processes have been developed. Among these processes, drag finishing involves immersing and moving the cutting tool in an abrasive media, where friction with the grains smooths the surfaces and modifies the cutting edge microgeometry (Tikal, \u003cspan citationid=\"CR7\" class=\"CitationRef\"\u003e2009\u003c/span\u003e). This media is generally composed of 3 materials: A filler material that transports the abrasive and contains larger grains.; an abrasive material with a smaller grain size that is responsible for the abrasive action of the media; and a high-viscosity adhesive oil that has the function of adhering the grains of the filler material to the grains of the abrasive material. The abrasive media are usually silicon carbide, ceramic, quartz, or plastic bonded abrasive particles (Wang et al., \u003cspan citationid=\"CR8\" class=\"CitationRef\"\u003e2020\u003c/span\u003e). The relative motion between tool and abrasive removes material from the surface, with particle size and composition being key to the removal rate (Tikal, \u003cspan citationid=\"CR7\" class=\"CitationRef\"\u003e2009\u003c/span\u003e).\u003c/p\u003e\u003cp\u003eSeveral studies have evaluated the impact of edge treatment on the milling process. One of them is Bouzakis et al. (\u003cspan citationid=\"CR9\" class=\"CitationRef\"\u003e2014\u003c/span\u003e), who evaluated different edge treatment methods on milling inserts for various materials. The study showed that cutting edge preparation can improve tool performance, with gains of up to 93% compared to untreated inserts, depending on the material machined and the technique used. In the study by Uhlmann et al. (\u003cspan citationid=\"CR10\" class=\"CitationRef\"\u003e2016\u003c/span\u003e), the authors tested micro-mills with and without edge treatment. The work revealed that the microgeometry of the cutting edge positively influences the cutting forces, tool wear and surface roughness of the machined part.\u003c/p\u003e\u003cp\u003eComparative studies have also explored the performance of different edge preparation techniques. Zeilmann et al. (\u003cspan citationid=\"CR11\" class=\"CitationRef\"\u003e2018\u003c/span\u003e) compared drag finishing and brushing with no edge preparation, focusing on surface quality in milling AISI P20. The authors concluded that both cutting edge preparation methods were effective in reducing the surface roughness of the workpiece, being that with drag finishing producing the most homogeneous finish. Hronek et al. (\u003cspan citationid=\"CR12\" class=\"CitationRef\"\u003e2018\u003c/span\u003e) compared drag finishing using HSC 1/300 and QZ 1\u0026ndash;3W media to water jet preparation, when machining Inconel 718. By testing cutting edge radii of 15 \u0026micro;m, 20 \u0026micro;m, and 25 \u0026micro;m, they found that drag finishing consistently offered better tool durability and surface finish, with the best performance at a 15 \u0026micro;m radius using HSC 1/300 media.\u003c/p\u003e\u003cp\u003eAlthough research on drag finishing and its application to cutting tools has been increasing, studies specifically addressing the role and characteristics of abrasive media remain limited, despite abrasive media being one of the key variables in the process. Among the main studies are those by Uhlmann et al. (\u003cspan citationid=\"CR13\" class=\"CitationRef\"\u003e2014\u003c/span\u003e), Malkorra et al. (\u003cspan citationid=\"CR14\" class=\"CitationRef\"\u003e2021\u003c/span\u003e), Lv et al. (\u003cspan citationid=\"CR15\" class=\"CitationRef\"\u003e2021\u003c/span\u003e)d rez-Salinas et al. (2022). In all cases, the abrasive media had a significant impact on the microgeometry and surface condition of the cutting edge.\u003c/p\u003e\u003cp\u003eThis new scientific contribution from this work is the evaluation of the effects of two commercial and one alternative media by analyzing changes in cutting edge geometry through detailed characterization techniques and this effect under the wear and behavior during the milling of AISI P20 and SAE 4140 steels.\u003c/p\u003e"},{"header":"2. Materials and methods","content":"\u003cp\u003eIn this section the experimental methodologies, equipment, tools, and materials used are presented to support the analysis, through an experimental plan, seen in Fig.\u0026nbsp;2.\u003c/p\u003e\u003cp\u003eRegarding the input data, the machining conditions for the experiment were maintained fixed, while the workpiece material consisted of two different types of steel. Also, in order to comprehend the impact of the drag finish, four different microgeometries of cemented end mills were generated using three different abrasive media. This directly influences the output data that was evaluated. Therefore, since the objective of this study was to analyze the wear of these cutting tools, a set of analysis was performed to reach this goal.\u003c/p\u003e\u003cdiv id=\"Sec3\" class=\"Section2\"\u003e\u003ch2\u003e2.1 Workpiece\u003c/h2\u003e\u003cp\u003eThese experimental tests were performed using two types of workpiece material with distinct hardness. The first workpiece utilized was an AISI P20 steel (W.Nr 1.2311; DIN X40CrMnMo7), a material frequently employed in the fabrication of plastic injection molds. It has undergone a hardening process, resulting in a 36\u0026thinsp;\u0026plusmn;\u0026thinsp;2 HRC hardness. Additionally, its chemical composition essentially contains 0.409 wt% C, 2.033 wt% Cr, 0.108 wt% Co, 0.119 wt% Cu, 0.716 wt% Ni, 1.462 wt% Mn, 0.201 wt% Mo, 0.022 wt% P, 0.377 wt% Si, 0.384 wt% S and Fe as balance. The workpiece size was 252 mm (l), 80 mm (w), 60 mm (h).\u003c/p\u003e\u003cp\u003eThe second material utilized was the SAE 4140 (DIN 42CrMo4), which had a measured hardness of 20\u0026thinsp;\u0026plusmn;\u0026thinsp;2 HRC. The chemical composition is 0.417 wt% C, 1,02 wt% Cr, 0.140 wt% Cu, 0.110 wt% Ni, 0.860 wt% Mn, 0.180 wt% Mo, 0.011 wt% P, 0.005 wt% S, 0.240 wt% Si and Fe as balance. The workpiece size is 200 mm (l), 80 mm (w) and 60 mm (h).\u003c/p\u003e\u003c/div\u003e\u003cdiv id=\"Sec4\" class=\"Section2\"\u003e\u003ch2\u003e2.2 Machining conditions and equipment\u003c/h2\u003e\u003cp\u003eFor the machining tests, the strategy adopted was to use down milling without cutting fluid (dry). The cutting speed (v\u003csub\u003ec\u003c/sub\u003e) and feed per tooth (f\u003csub\u003ez\u003c/sub\u003e) were set at 180 m/min and 0.05 mm/tooth, respectively, while the axial (a\u003csub\u003ep\u003c/sub\u003e) and radial (a\u003csub\u003ee\u003c/sub\u003e) depths of cut were 0.5 mm and 0.2 mm, respectively. The ratio length/diameter was three. The cutting parameters were fixed in all tests. These cutting conditions were defined in pre-tests. Figure\u0026nbsp;3 illustrates the milling process and the conditions used.\u003c/p\u003e\u003cp\u003eEvery 5040 mm of linear cutting, the tool was removed from the machine to inspect and measure the tool wear. The tool life criterion established in this experiment is \u003cspan class=\"InlineEquation\"\u003e\u003cspan class=\"mathinline\"\u003e\\(\\:{VB}_{max}\\)\u003c/span\u003e\u003c/span\u003e = 0.2 mm or noticeable cutting edge chipping. End of test criterion was set to a linear distance of 30 m for the machining of AISI P20 and 50 m for machining the SAE 4140 steel. Two cutting tools for each microgeometry condition were used, to ensure a reliable result.\u003c/p\u003e\u003cp\u003eThe CNC machine utilized was a Hartford LG-500, with a power of 12 kW and maximum spindle speed of 10,000 rpm. The end mills were fixed using a hydraulic expansion toolholder, manufactured by Schunk, model TENDO E compact.\u003c/p\u003e\u003cp\u003eProceeding the characterization, for the macroscopic view, an Entex TNE-10B stereoscope was used, in conjunction with a CCD camera to capture images of the tools. For a better understanding of the microgeometry of the end mills, a Scanning Electron Microscopy (SEM), made by Tescan model Mira 3 was utilized to characterize the new and used tools. To verify the cutting edge parameters and microgeometry, an optical 3D measurement device made by Alicona, model Edge Master, was utilized.\u003c/p\u003e\u003c/div\u003e\u003cdiv id=\"Sec5\" class=\"Section2\"\u003e\u003ch2\u003e2.3 Cutting Tool\u003c/h2\u003e\u003cp\u003eThe end mills used on the machining tests were developed exclusively by the tests and manufactured by Secta Tools. Figure\u0026nbsp;4 shows the tool, with information about the macrogeometry.\u003c/p\u003e\u003cp\u003eFor the experiment, 6 mm diameter tools were used, with four cutting edges and without coating. The substrate was cemented carbide (WC), ISO K40 grade with 10% Co, manufactured by the Ceratizit Group, with ISO h6 tolerance. The material characteristics include an average WC grain size between 0.5 and 0.8 \u0026micro;m (submicron class) and a hardness of 1600 HV30.\u003c/p\u003e\u003c/div\u003e\u003cdiv id=\"Sec6\" class=\"Section2\"\u003e\u003ch2\u003e2.4 Cutting edge treatment\u003c/h2\u003e\u003cp\u003eFor the cutting edge preparation, the tools were treated by a drag finish process. To analyze the influence of the three abrasive media: HSC 1/300 (1/300), H4/400 (4/400) and a non-commercial media proposed by the authors called Zirconite (ZR). A sharpened tool (SH) was used as the reference condition.\u003c/p\u003e\u003cp\u003eOTEC Pr\u0026auml;zisionsfinish GmbH supplied the HSC 1/300 and H 4/400 abrasive media. HSC 1/300 consists of a mixture containing 30% silicon carbide (SiC) with a grain size of \u0026asymp;\u0026thinsp;200 \u0026micro;m and 70% walnut shell granules with grain sizes between 800 and 1300 \u0026micro;m. H 4/400, on the other hand, is composed of walnut shell granules with grain sizes between 400 and 800 \u0026micro;m and a polishing paste containing diamond particles (Uhlmann, 2014; Uhlmann, 2016). The edge treatment with HSC 1/300 and H 4/400 was performed using an OTEC SF-3 machine.\u003c/p\u003e\u003cp\u003eThe non-commercial media proposed by research group consists mainly of peanut shell granules (with a grain diameter between 841 \u0026micro;m and 1410 \u0026micro;m) and Zirconite (ZrSi\u003cspan class=\"InlineEquation\"\u003e\u003cspan class=\"mathinline\"\u003e\\(\\:{O}_{4}\\)\u003c/span\u003e\u003c/span\u003e) (with a grain diameter of between 149 \u0026micro;m and 210 \u0026micro;m). The proportions of these two components in the abrasive media are 70% and 30%, respectively. As illustrated in Fig.\u0026nbsp;5, the procedure for obtaining the media and its components is as follows.\u003c/p\u003e\u003cp\u003ePeanut shells were separated from the grain and dried in the oven, to eliminate the moisture. A knife mill was used to grind the shells in a constant rotation. A vibrating sieve was used to sift the shell in the desired particle size, between mesh 14 and 20. The result was a controlled particle size diameter (0,8 to 1,41 mm). On the other hand, Zirconite was obtained in various particle sizes, requiring the use of a vibration sieve in order to control the particle sizes between the sieves of mesh 65 and 100. Particle size was between 150 and 210 \u0026micro;m. The mixing process mainly consists in adding 2,00 ml of OTEC adhesive oil in a container with the peanut shells, during 20 minutes. Zirconite was slowly added to the mixture over a period of 10 minutes, concluding the process.\u003c/p\u003e\u003cp\u003eThe cutting edge preparation using ZR abrasive media was carried out with some characteristics that distinguished it from the approach employed by OTEC. Due to the size difference between the industrial container used at the OTEC factory and the laboratory setup adopted in this work, the drag finishing parameters for ZR were specifically adjusted to match the tangential contact velocity applied with the 1/300 and 4/400 abrasive media. Table\u0026nbsp;\u003cspan refid=\"Tab1\" class=\"InternalRef\"\u003e1\u003c/span\u003e shows the specified parameters done in the different media.\u003c/p\u003e\u003cp\u003e\u003cdiv class=\"gridtable\"\u003e\u003ctable float=\"Yes\" id=\"Tab1\" border=\"1\"\u003e\u003ccaption language=\"En\"\u003e\u003cdiv class=\"CaptionNumber\"\u003eTable 1\u003c/div\u003e\u003cdiv class=\"CaptionContent\"\u003e\u003cp\u003eDrag finish process parameters\u003c/p\u003e\u003c/div\u003e\u003c/caption\u003e\u003ccolgroup cols=\"5\"\u003e\u003cdiv align=\"left\" class=\"colspec\" colname=\"c1\" colnum=\"1\"\u003e\u003c/div\u003e\u003cdiv align=\"left\" class=\"colspec\" colname=\"c2\" colnum=\"2\"\u003e\u003c/div\u003e\u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c3\" colnum=\"3\"\u003e\u003c/div\u003e\u003cdiv align=\"left\" class=\"colspec\" colname=\"c4\" colnum=\"4\"\u003e\u003c/div\u003e\u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c5\" colnum=\"5\"\u003e\u003c/div\u003e\u003cthead\u003e\u003ctr\u003e\u003cth align=\"left\" colname=\"c1\"\u003e\u003cp\u003eAbrasive Media\u003c/p\u003e\u003c/th\u003e\u003cth align=\"left\" colname=\"c2\"\u003e\u003cp\u003eType of process\u003c/p\u003e\u003c/th\u003e\u003cth align=\"left\" colname=\"c3\"\u003e\u003cp\u003eTime of Process (sec)\u003c/p\u003e\u003c/th\u003e\u003cth align=\"left\" colname=\"c4\"\u003e\u003cp\u003eDirection\u003c/p\u003e\u003c/th\u003e\u003cth align=\"left\" colname=\"c5\"\u003e\u003cp\u003eRotation of the Tool (rpm)\u003c/p\u003e\u003c/th\u003e\u003c/tr\u003e\u003c/thead\u003e\u003ctbody\u003e\u003ctr\u003e\u003ctd align=\"left\" colname=\"c1\"\u003e\u003cp\u003e1/300\u003c/p\u003e\u003c/td\u003e\u003ctd align=\"left\" colname=\"c2\"\u003e\u003cp\u003eDry Polishing\u003c/p\u003e\u003c/td\u003e\u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e\u003cp\u003e30\u003c/p\u003e\u003c/td\u003e\u003ctd align=\"left\" colname=\"c4\"\u003e\u003cp\u003eClockwise\u003c/p\u003e\u003c/td\u003e\u003ctd align=\"char\" char=\".\" colname=\"c5\"\u003e\u003cp\u003e40\u003c/p\u003e\u003c/td\u003e\u003c/tr\u003e\u003ctr\u003e\u003ctd align=\"left\" colname=\"c1\"\u003e\u003cp\u003e4/400\u003c/p\u003e\u003c/td\u003e\u003ctd align=\"left\" colname=\"c2\"\u003e\u003cp\u003eDry Polishing\u003c/p\u003e\u003c/td\u003e\u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e\u003cp\u003e120\u003c/p\u003e\u003c/td\u003e\u003ctd align=\"left\" colname=\"c4\"\u003e\u003cp\u003eClockwise\u003c/p\u003e\u003c/td\u003e\u003ctd align=\"char\" char=\".\" colname=\"c5\"\u003e\u003cp\u003e40\u003c/p\u003e\u003c/td\u003e\u003c/tr\u003e\u003ctr\u003e\u003ctd align=\"left\" colname=\"c1\"\u003e\u003cp\u003eZR\u003c/p\u003e\u003c/td\u003e\u003ctd align=\"left\" colname=\"c2\"\u003e\u003cp\u003eWet Polishing\u003c/p\u003e\u003c/td\u003e\u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e\u003cp\u003e600\u003c/p\u003e\u003c/td\u003e\u003ctd align=\"left\" colname=\"c4\"\u003e\u003cp\u003eClockwise\u003c/p\u003e\u003c/td\u003e\u003ctd align=\"char\" char=\".\" colname=\"c5\"\u003e\u003cp\u003e265\u003c/p\u003e\u003c/td\u003e\u003c/tr\u003e\u003c/tbody\u003e\u003c/colgroup\u003e\u003c/table\u003e\u003c/div\u003e\u003c/p\u003e\u003cp\u003eThe drag finishing parameters have a direct influence on the cutting edge radius produced. Risse (\u003cspan citationid=\"CR17\" class=\"CitationRef\"\u003e2006\u003c/span\u003e) and Voz\u0026aacute;r et al. (2020) tested different parameter combinations to compare the influence of each parameter in the cutting edge radius. In their results, the rotation of the tool was the most important parameter, since it determines the rate of material removal. The processing time is a variable that makes an important contribution to the rounding of the cutting edge. Uhlmann et al. (\u003cspan citationid=\"CR13\" class=\"CitationRef\"\u003e2014\u003c/span\u003e) investigated the material removal as a function of processing time using different types of media. They observed faster material removal with the HSC 1/300 medium compared to the H 4/400 medium. Therefore, in this experiment, combinations of parameters were used with the aim of achieving a comparable cutting edge radius.\u003c/p\u003e\u003c/div\u003e"},{"header":"3. Results","content":"\u003cp\u003eThe following results show the correlation between edge preparation by the drag process, using different abrasive media with the wear of end mills. Therefore, machining tests were carried out, using a standard tool as a reference, followed by tools with the prepared cutting edge. Wear was measured progressively and an end-of-life criterion was established and the results discussed.\u003c/p\u003e\u003cdiv id=\"Sec8\" class=\"Section2\"\u003e\u003ch2\u003e3.1 Cutting Tool Characterization\u003c/h2\u003e\u003cp\u003eAn important way to obtain reliable information about the impact of the cutting edge preparation on the tool microgeometry is through a characterization. The infinity focus system of the Alicona Edge Master Series was used to measure the microtopography and contour of the cutting edge, providing numerical results. Table\u0026nbsp;\u003cspan refid=\"Tab2\" class=\"InternalRef\"\u003e2\u003c/span\u003e contains the characterization parameters from the cutting edge for the microgeometries conditions.\u003c/p\u003e\u003cp\u003e\u003cdiv class=\"gridtable\"\u003e\u003ctable float=\"Yes\" id=\"Tab2\" border=\"1\"\u003e\u003ccaption language=\"En\"\u003e\u003cdiv class=\"CaptionNumber\"\u003eTable 2\u003c/div\u003e\u003cdiv class=\"CaptionContent\"\u003e\u003cp\u003eCutting edge characterization parameters\u003c/p\u003e\u003c/div\u003e\u003c/caption\u003e\u003ccolgroup cols=\"6\"\u003e\u003cdiv align=\"left\" class=\"colspec\" colname=\"c1\" colnum=\"1\"\u003e\u003c/div\u003e\u003cdiv align=\"left\" class=\"colspec\" colname=\"c2\" colnum=\"2\"\u003e\u003c/div\u003e\u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c3\" colnum=\"3\"\u003e\u003c/div\u003e\u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c4\" colnum=\"4\"\u003e\u003c/div\u003e\u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c5\" colnum=\"5\"\u003e\u003c/div\u003e\u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c6\" colnum=\"6\"\u003e\u003c/div\u003e\u003cthead\u003e\u003ctr\u003e\u003cth align=\"left\" colname=\"c1\"\u003e\u003cp\u003eEdge Condition\u003c/p\u003e\u003c/th\u003e\u003cth align=\"left\" colname=\"c2\"\u003e\u003cp\u003e\u003cspan class=\"InlineEquation\"\u003e\u003cspan class=\"mathinline\"\u003e\\(\\:{r}_{\\beta\\:}\\)\u003c/span\u003e\u003c/span\u003e (\u0026micro;m)\u003c/p\u003e\u003c/th\u003e\u003cth align=\"left\" colname=\"c3\"\u003e\u003cp\u003eSα (\u0026micro;m)\u003c/p\u003e\u003c/th\u003e\u003cth align=\"left\" colname=\"c4\"\u003e\u003cp\u003eSγ (\u0026micro;m)\u003c/p\u003e\u003c/th\u003e\u003cth align=\"left\" colname=\"c5\"\u003e\u003cp\u003eK (-)\u003c/p\u003e\u003c/th\u003e\u003cth align=\"left\" colname=\"c6\"\u003e\u003cp\u003eΔr (\u0026micro;m)\u003c/p\u003e\u003c/th\u003e\u003c/tr\u003e\u003c/thead\u003e\u003ctbody\u003e\u003ctr\u003e\u003ctd align=\"left\" colname=\"c1\"\u003e\u003cp\u003eSH\u003c/p\u003e\u003c/td\u003e\u003ctd align=\"left\" colname=\"c2\"\u003e\u003cp\u003e3,904\u003c/p\u003e\u003c/td\u003e\u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e\u003cp\u003e15.981\u003c/p\u003e\u003c/td\u003e\u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e\u003cp\u003e2.196\u003c/p\u003e\u003c/td\u003e\u003ctd align=\"char\" char=\".\" colname=\"c5\"\u003e\u003cp\u003e0.137\u003c/p\u003e\u003c/td\u003e\u003ctd align=\"char\" char=\".\" colname=\"c6\"\u003e\u003cp\u003e3.339\u003c/p\u003e\u003c/td\u003e\u003c/tr\u003e\u003ctr\u003e\u003ctd align=\"left\" colname=\"c1\"\u003e\u003cp\u003e1/300\u003c/p\u003e\u003c/td\u003e\u003ctd align=\"left\" colname=\"c2\"\u003e\u003cp\u003e7.653\u003c/p\u003e\u003c/td\u003e\u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e\u003cp\u003e11.626\u003c/p\u003e\u003c/td\u003e\u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e\u003cp\u003e11.047\u003c/p\u003e\u003c/td\u003e\u003ctd align=\"char\" char=\".\" colname=\"c5\"\u003e\u003cp\u003e0.950\u003c/p\u003e\u003c/td\u003e\u003ctd align=\"char\" char=\".\" colname=\"c6\"\u003e\u003cp\u003e6.017\u003c/p\u003e\u003c/td\u003e\u003c/tr\u003e\u003ctr\u003e\u003ctd align=\"left\" colname=\"c1\"\u003e\u003cp\u003e4/400\u003c/p\u003e\u003c/td\u003e\u003ctd align=\"left\" colname=\"c2\"\u003e\u003cp\u003e8.287\u003c/p\u003e\u003c/td\u003e\u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e\u003cp\u003e14.697\u003c/p\u003e\u003c/td\u003e\u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e\u003cp\u003e12.645\u003c/p\u003e\u003c/td\u003e\u003ctd align=\"char\" char=\".\" colname=\"c5\"\u003e\u003cp\u003e0.860\u003c/p\u003e\u003c/td\u003e\u003ctd align=\"char\" char=\".\" colname=\"c6\"\u003e\u003cp\u003e6.408\u003c/p\u003e\u003c/td\u003e\u003c/tr\u003e\u003c/tbody\u003e\u003c/colgroup\u003e\u003c/table\u003e\u003c/div\u003e\u003c/p\u003e\u003cp\u003eThe tools were treated by OTEC Pr\u0026auml;zisionsfinish GmbH in Germany using the HSC 1/300 and H 4/400 abrasive media. A complete characterization was carried out on the tools in both sharpened and treated conditions. However, the edge preparation of the tools with ZR media was performed by the research group at the University of Caxias do Sul, and a more detailed characterization was not possible. The SEM images (Fig.\u0026nbsp;6) show that the cutting edge topography in the ZR condition is similar to the standard condition. The hypothesis is that the cutting edge rounding radius \u003cspan class=\"InlineEquation\"\u003e\u003cspan class=\"mathinline\"\u003e\\(\\:{r}_{\\beta\\:}\\)\u003c/span\u003e\u003c/span\u003e in the ZR condition is greater than that of the standard condition but smaller than in the other treated conditions.\u003c/p\u003e\u003cp\u003eSharpened tool (SH) is the untreated edge and has been considered the ground tool for this experiment. During tool manufacturing, the meeting of the abrasive grinding wheels generates a sharp cutting edge, and the properties presented in abrasive grains can directly impact the surface finishing (Denkena and Biermann, \u003cspan citationid=\"CR2\" class=\"CitationRef\"\u003e2014\u003c/span\u003e). Results show the SH tool has the smallest cutting edge radius \u003cspan class=\"InlineEquation\"\u003e\u003cspan class=\"mathinline\"\u003e\\(\\:{r}_{\\beta\\:}\\)\u003c/span\u003e\u003c/span\u003e. The value of K factor was closer to zero, indicating that the cutting edge contour has a waterfall geometry. Conditions as presented show an irregular surface all along the cutting edge, therefore, the largest deviation of the four conditions.\u003c/p\u003e\u003cp\u003eOn the other hand, the drag finishing process using HSC 1/300 and H 4/400 media increased the edge radius by 96% and 112%, respectively, compared to the SH tool. The dispersion of the radius values along the section measured is reduced for the HSC 1/300 and H 4/400 tools. Authors such as Uhlmann et al. (\u003cspan citationid=\"CR13\" class=\"CitationRef\"\u003e2014\u003c/span\u003e) and Zeilmann et al. (\u003cspan citationid=\"CR11\" class=\"CitationRef\"\u003e2018\u003c/span\u003e) also reported an increase in the cutting edge radius and a reduction in tool surface roughness. This behavior is expected in tools that were prepared, since the edge material is removed within the process, leveling the surface.\u003c/p\u003e\u003cp\u003eFigure 6 presents the characterization performed using a Tescan Mira 3 SEM. The image provides a detailed image of the flank face and rake face of the tools before the experimental tests. It is possible to see that the unprepared tool (SH) has several grinding marks on the flank face and rake face and edge chipping.\u003c/p\u003e\u003cp\u003eRegarding the 1/300 media, improvements can be seen in the surface of the edge, exhibiting a significant reduction in defects and grinding marks on the face and flank of the tools. Also, the micro-chipping previously present was eliminated for the traditionally verified viewing. The removal of material from the surface of the edge ends up making changes to the topography of the edge. Peaks and valleys that were previously protruding have been reduced or leveled out, affecting the surface roughness of the sample. Consequently, this results in a homogeneous roundness along the edge. As indicated in the works of D Lv et al. (2022) and Bordin and Zeilmann (\u003cspan citationid=\"CR18\" class=\"CitationRef\"\u003e2014\u003c/span\u003e), the utilization of the same abrasive media for edge treatment led to similar results.\u003c/p\u003e\u003cp\u003eFor the 4/400 tool, it is noticeable that the majority of the defects and marks are eliminated. This is the desired effect of edge preparation, and depending on the media utilized, the surface of the tool responds differently. A finer particle media requires more process time to obtain the same rounding as a rougher media, but the benefit is a refinement of the surface. H 4/400 media have diamond abrasive in its composition, due to a low particle granulometry, rugosity can be lowered when applied this media\u003c/p\u003e\u003cp\u003eThe ZR tool shows a poor surface quality compared to the prepared end mills, and it is still possible to see the marks generated by the grinding process on both the rake face and the flank face. A serrated texture can be observed near the cutting edge, as on the SH tool, which is not seen on the other treated tools. This phenomenon can be attributed to the resulting Zirconite and peanut shell size particles, which are larger than expected and are not evenly distributed. It has been established that variations in the process may have a direct impact on the abrasive potential of the media, resulting in a less refined surface when compared to that produced by the H 4/400 and HSC 1/300 media. It is further corroborated by the fact that the tangential speed of the ZR tool was identical to that employed in H 1/300 and H 4/400 media, and the process time was 400% longer. ZR only achieved a small improvement in surface quality compared to the SH tool.\u003c/p\u003e\u003c/div\u003e\u003cdiv id=\"Sec9\" class=\"Section2\"\u003e\u003ch2\u003e3.2 Tool Wear\u003c/h2\u003e\u003cp\u003eTo address the effect on the wear made by the edge preparation process, it is appropriate to perform a tool behavior curve. This demonstrates how the tool responded to a specific cutting length, thereby making it possible to evaluate the influence of edge treatment.\u003c/p\u003e\u003cdiv id=\"Sec10\" class=\"Section3\"\u003e\u003ch2\u003e3.2.1 AISI P20\u003c/h2\u003e\u003cp\u003eThe first analyzed material was the AISI P20 mold steel. In Fig.\u0026nbsp;7, it is possible to see the tools in their new state, and after reaching the established end-of-life criterion of 0.20 mm (VBmax). All the new tools had no macro-defects such as burrs or chipping that would interfere with the tests. The tools were monitored and measured according to the specified interval, in order to properly control the wear behavior and types of wear present on the tools.\u003c/p\u003e\u003cp\u003eDuring the experimental tests, the cutting tools primarily showed the abrasive wear mechanism. In general, flank wear was regular among the four conditions. Abrasion, identified by scoring marks on the cutting edge, naturally occurs under cutting friction contact, which is typical when machining this type of material (Wu et al., 2020). Minor chipping of the cutting edge was mainly observed on the SH and ZR tools. This can be attributed to the cutting edge radius, since a smaller radius, as encountered in both ZR and SH conditions, provides lower resistance to fracture, leading to the incidence of chipping throughout the cut. In addition, this is intensified by the fact that milling is an interrupted cutting process, with tool entry and exit impacts that subject it to cyclic thermal and mechanical loads (Hopkins et al., 2024).\u003c/p\u003e\u003cp\u003eAn SEM image of the SH and 1/300 tool when reaching the end of the test criterion (30 linear meters) can be seen in Fig.\u0026nbsp;8. The adhesion mechanism, although it was difficult to identify in the optical microscope, was evident in the SEM. Adhesion occurs under high temperatures and compressive stress, and severe adhesive wear usually appears before the tool reaches its normal wear life (Liu et al., \u003cspan citationid=\"CR20\" class=\"CitationRef\"\u003e2018\u003c/span\u003e). In all microgeometry conditions the same mechanisms and types of wear were observed.\u003c/p\u003e\u003cp\u003eFor AISI P20 steel, the wear behavior of the tools is shown in Fig.\u0026nbsp;9. The H 4/400 tool exhibited the least flank wear, from the beginning of the cut to the end-of-life criterion, when compared to the other microgeometry conditions. The SH, HSC 1/300, and ZR tools showed similar tool wear up to 10 meters.\u003c/p\u003e\u003cp\u003eAfter this cutting length, the other treated tools followed practically the same wear level during the test. The sharpened tool, on the other hand, resulted in the highest flank wear among the four conditions. During the manufacturing of the cutting tool, the sharpening process generates grinding marks. Depending on the orientation of these marks, they can negatively impact the tool life, as the chip follows against the marks, thereby raising both the friction and the local temperature (Denkena et al., \u003cspan citationid=\"CR21\" class=\"CitationRef\"\u003e2013\u003c/span\u003e). Furthermore, the sharpening promotes typical cutting edge defects such as micro-burrs, micro-chipping and an overall poor surface quality. This factor influences the stability of the cutting edge and reliability of the process, reducing the tool life and leading to an uneven wear behavior (Rech, 2005).\u003c/p\u003e\u003cp\u003eDepending on the form factor K = \u003cspan class=\"InlineEquation\"\u003e\u003cspan class=\"mathinline\"\u003e\\(\\:\\frac{S\\gamma\\:}{S\\alpha\\:}\\)\u003c/span\u003e\u003c/span\u003e, the primary wear mechanism can be different. For tools with an asymmetrical radius (K \u0026gt;1), there is a tendency to increase tool life. Higher values of \u003cspan class=\"InlineEquation\"\u003e\u003cspan class=\"mathinline\"\u003e\\(\\:S\\alpha\\:\\)\u003c/span\u003e\u003c/span\u003e results in a higher flank wear (Denkena 2011; Denkena 2012). Since the SH condition has a low factor form K = 0.137, it was observed that this condition had the most flank wear among the tools. Symmetrical cutting edges (K = 1) provide a higher mechanical stability, leading to a low occurrence of chipping. Denkena et al, \u003cspan citationid=\"CR25\" class=\"CitationRef\"\u003e2009\u003c/span\u003e performed an experiment using an uncoated cemented carbide milling tool with the edge preparation and form factor K\u0026thinsp;=\u0026thinsp;1, the results show an enhanced in the tool\u0026rsquo;s life in 70% when machining Ti6Al4V. Thus, the results obtained for the cutting edge radius and the form factor K indicate values close to 1 and, therefore, caused the improvement in the tool life for the drag finish with HSC 1/300 and H 4/400 media. Zirconite media also reduce the flank wear, but with no information on the form factor K value.\u003c/p\u003e\u003c/div\u003e\u003cdiv id=\"Sec11\" class=\"Section3\"\u003e\u003ch2\u003e3.2.2 SAE 4140\u003c/h2\u003e\u003cp\u003eThe same procedure performed in the AISI P20 material was executed for the SAE 4140. Figure\u0026nbsp;10 illustrates the tools when reaching the tool life criterion. Since this material was not subjected to a hardening treatment, its hardness is lower in comparison to AISI P20. Consequently, the mechanical stresses on the cutting edge did not result in any defects, such as chipping or breakage. In addition, the identified wear mechanisms were abrasion and adhesion, which are consistent with the findings for AISI P20.\u003c/p\u003e\u003cp\u003eIn Fig.\u0026nbsp;11. is possible to see the wear behavior of the cutting tools when machining SAE 4140 steel. The wear behavior of the four microgeometry conditions remained constant and similar up to the 20 linear cutting length.\u003c/p\u003e\u003cp\u003eAfter 20 meters, the H 4/400 tool showed high wear compared to the other tools, reaching the end-of-life criterion with a shorter linear cutting length. From this point onwards, the deviation of the values was the highest among all the conditions, which indicates a discrepancy between the wear of the individual's cutting edge. This can be attributed to an increased cutting edge radius, since the H 4/400 have a higher radius. As the radius of the tool increases, the ploughing effect occurs, in which material is trapped in the cutting edge of the tool and is pushed towards the tool flank, not effectively cutting the material, but deforming it. The cutting forces rise, as well as the residual stress. negatively affect the tool's wear behavior. For the HSC 1/300 and SH tools, similar wear behavior throughout the cut, reaching the tool life criterion in almost the same cutting length, favoring the SH condition. Both conditions have a lower cutting edge radius than the H 4/400 tool. ZR media resulted in the least tool wear among all conditions. Nardy et al (\u003cspan citationid=\"CR26\" class=\"CitationRef\"\u003e2024\u003c/span\u003e) performed a hard turning test in a SAE 4140 workpiece, but in the hardened condition, exhibiting around 50 HRC. The main comparison was the different approach to factor form K. In the results, the factor form K\u0026thinsp;=\u0026thinsp;1 and K\u0026thinsp;=\u0026thinsp;2 of the grinded edge prepared inserts showed the least tool wear, compared to the sharp unprepared insert. In this case, the severity of the process combined with a higher hardened material favors the higher rounding, since the contact area is increased, the cutting pressure is reduced, enhancing the tool life. On the other hand, in the work proposed by Bouzakis 2014, using the equivalent material (42CrMo4) and several preparation methods, including drag finishing, results shows that smaller cutting edge radius, without preparation, resulted in a better tool life. The elevated temperatures generated by the rounded cutting edge, typically higher than those of tools without edge preparation, can alter the workpiece microstructure, potentially affecting its machinability. These results highlight that the material condition can significantly influence tool life. SAE 4140 steel is widely used in industrial applications due to its good hardenability (Irsel et al., 2022). Also, size of the radius in which the tools performance is higher depends on a number of factors such as the workpiece material and its mechanical properties, cutting parameters and tools macrogeometry (Tikal, \u003cspan citationid=\"CR7\" class=\"CitationRef\"\u003e2009\u003c/span\u003e; Denkena and Biermann, \u003cspan citationid=\"CR2\" class=\"CitationRef\"\u003e2014\u003c/span\u003e).\u003c/p\u003e\u003c/div\u003e\u003cdiv id=\"Sec12\" class=\"Section3\"\u003e\u003ch2\u003e3.2.3 Cutting Length\u003c/h2\u003e\u003cp\u003eFor both workpiece materials, the cutting tool life is presented in Fig.\u0026nbsp;12.\u003c/p\u003e\u003cp\u003eWhen machining AISI P20 the SH tool resulted in the lowest cutting length, completing 16.2 meters when reaching the maximum flank wear. The smaller cutting edge radius and the surface defects generated from the grinding process negatively affected the performance. For the ZR and HSC 1/300 tools, cutting edge preparation increased the tool's performance, resulting in a 5% improvement in the total number of linear meters machined. The tool treated with the H 4/400 media showed a 19% increased tool life than the SH. The dispersion of the values was adequate between the four conditions tested. These results are in agreement with other authors that machining materials with similar hardness. Barbosa et al. (\u003cspan citationid=\"CR28\" class=\"CitationRef\"\u003e2021\u003c/span\u003e), carried out a test using an end mill with and without cutting edge preparation on a similar material VP20TS, and described a reduction in wear of the treated tool and an improvement in the machined surface.\u003c/p\u003e\u003cp\u003eTo SAE 4140 steel, the H 4/400 media tool machined almost five linear meters less than SH tool, which reduced the tool life by 16%. These two microgeometry conditions resulted in a low deviation, pointing to a suitable performance. HSC 1/300 media resulted in a 1% reduction in the tool life. Meanwhile, the drag finishing process using Zirconite abrasive media resulted in an increase in the end mill life by almost 10%. Wang et al. (\u003cspan citationid=\"CR8\" class=\"CitationRef\"\u003e2020\u003c/span\u003e) reported a 168% improvement in tool life when machining AISI 4140 steel in orthogonal turning using drag-finished inserts.\u003c/p\u003e\u003cp\u003eHowever, in two microgeometries conditions (ZR and 1/300) a large deviation of the values was observed. Some factors may have influenced this discrepancy in the results. In the case of the drag finishing process, the operations were carried out in a strictly similar manner for all tools, respecting the selected process parameters. A possible variation can be attributed to the workpiece. Since it varied with each tool, some differences between workpiece materials are expected, but not enough to generate this abnormal discrepancy in machined length. The most plausible hypothesis could be some variation in the tool manufacturing process. During the grinding process, the abrasive wheels that are used to determine the macrogeometry of the tool may be interfered with, resulting in a cutting tool that is out of specification. This has a direct influence on the cutting mechanics and consequently on wear behavior.\u003c/p\u003e\u003c/div\u003e\u003c/div\u003e"},{"header":"4. Conclusions","content":"\u003cp\u003eEdge preparation constitutes a critical stage in the manufacturing of cutting tools. Among the available techniques, drag finishing is widely recognized for its effectiveness in promoting cutting-edge rounding. In this study, a comprehensive investigation was conducted into the use of different abrasive media, with the aim of elucidating their direct influence on tool performance and machining behavior.\u003c/p\u003e\u003cp\u003eThus, the following main findings were made:\u003c/p\u003e\u003cp\u003e\u003col\u003e\u003cspan\u003e\u003cli\u003e\u003cp\u003eSignificant improvements in tool microgeometry and surface finish were observed following edge preparation. Defects previously identified in the SH tool were successfully eliminated. Among the tested media, H 4/400 demonstrated the highest effectiveness in removing such defects and homogenizing the microtopography.\u003c/p\u003e\u003c/li\u003e\u003c/span\u003e\u003cspan\u003e\u003cli\u003e\u003cp\u003eIn general, tools subjected to edge preparation exhibited superior tool life compared with the sharpened tool. Across all experimental conditions, the types and mechanisms of wear remained consistent. All abrasive media applied in the drag finishing process enhanced cutting tool life during the machining of AISI P20 steel. Specifically, the HSC 1/300 and Zirconite media extended tool life by approximately 6%, whereas the H 4/400 medium achieved an improvement of nearly 20%.\u003c/p\u003e\u003c/li\u003e\u003c/span\u003e\u003cspan\u003e\u003cli\u003e\u003cp\u003eWith regard to SAE 4140 steel, the sharpened tool (SH) proved to be the most reliable, as indicated by its lower variability in tool life measurements. In contrast, the H 4/400 medium resulted in a reduction of 16% in tool life, while HSC 1/300 led to a 1% reduction. The Zirconite (ZR) medium, however, produced an increase of 10% in cutting length, albeit with higher deviations in results, similarly observed for both HSC 1/300 and Zirconite media.\u003c/p\u003e\u003c/li\u003e\u003c/span\u003e\u003cspan\u003e\u003cli\u003e\u003cp\u003eThe alternative Zirconite (ZR) medium, proposed by the research group, was shown to be a promising candidate for application in the drag finishing process. Its influence on tool life was favorable, as evidenced by improvements in comparison with the SH tool across both workpiece materials. Nevertheless, the surface finish of the cutting edge was inferior to that obtained with OTEC media, as residual defects originating from the manufacturing process persisted. Future refinement of the abrasive medium is therefore recommended to further enhance its effectiveness.\u003c/p\u003e\u003c/li\u003e\u003c/span\u003e\u003c/ol\u003e\u003c/p\u003e"},{"header":"Declarations","content":"\u003cp\u003e\u003cstrong\u003eCompeting interests\u003c/strong\u003e\u003cp\u003eThe authors declare no competing interests.\u003c/p\u003e\u003c/p\u003e\u003ch2\u003eFunding\u003c/h2\u003e\u003cp\u003eThis work was supported by Luccas A P Delgado, Jean L N Subtil and Rodrigo P Zeilmann with support from OTEC and University of Caxias do Sul, Capes, and CNPq.\u003c/p\u003e\u003ch2\u003eAuthors\u0026rsquo; Contribution\u003c/h2\u003e\u003cp\u003eAll authors contributed to the study conception and design.\u003c/p\u003e\u003ch2\u003eAcknowledgements\u003c/h2\u003e\u003cp\u003eThe authors would like to thank the University of Caxias do Sul for providing the facilities to carry out the experiment, OTEC Pr\u0026auml;zisionsfinish GmbH (Germany), for their partnership and preparation of the drag finishing tools, Secta Tools for providing the tools, CNPQ and CAPES for their scholarship and support.\u003c/p\u003e"},{"header":"References","content":"\u003col start=\"1\" type=\"1\"\u003e\n\u003cli\u003ePoulachon G, Bandyopadhyay BP, Jawahir IS, Pheulpin S, Seguin E (2004) Wear behavior of CBN tools while turning various hardened steels. Wear 56:302\u0026ndash;310. https://doi.org/10.1016/S0043-1648(03)00414-9\u003c/li\u003e\n\u003cli\u003eDenkena B, Biermann D (2014) Cutting edge geometries. CIRP Annals - Manufacturing Technology 63: 631\u0026ndash;653. http://dx.doi.org/10.1016/j.cirp.2014.05.009. \u003c/li\u003e\n\u003cli\u003eKlocke F (2018) Fertigungsverfahren 1: Zerspanung mit geometrisch bestimmter schneide. \u003c/li\u003e\n\u003cli\u003eDenkena B, Becker C, De Leon-Garcia L (2005) Study of the influence of the cutting edge microgeometry on the cutting forces and wear behavior in turning operations. 8th CIRP International Workshop on Modelling of Machining Operations: 503-507. \u003c/li\u003e\n\u003cli\u003eRodr\u0026iacute;guez, C. 2009. \u0026ldquo;Cutting edge preparation of precision cutting tools by applying micro-abrasive jet machining and brushing\u0026rdquo;. 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The International Journal of Advanced Manufacturing Technology 106: 1823\u0026ndash;1838. https://doi.org/10.1007/s00170-019-04702-1 \u003c/li\u003e\n\u003cli\u003eBouzakis K D, Bouzakis E, Kombogiannis S, Makrimallakis S, Skordaris G, Michailidis N, Charalampous P, Paraskevopoulou R, M\u0026apos;Saoubi R, Aurich J C, Barthelm\u0026auml; F, Biermann D, Denkena B, Dimitrov D, Engin S, Karpuschewski B, Klocke F, \u0026Ouml;zel T, Poulachon G, Rech J, Schulze V, Settineri L, Srivastava A, Wegener K, Uhlmann E, Zeman P (2014) Effect of cutting edge preparation of coated tools on their performance in milling various materials. CIRP Journal of Manufacturing Science and Technology 7: 264\u0026ndash;273. https://doi.org/10.1016/j.cirpj.2014.05.003\u003c/li\u003e\n\u003cli\u003eUhlmann E, Oberschmidt D, Kuche Y, L\u0026ouml;wenstein A, Winker I (2016) Effects of Different Cutting Edge Preparation Methods on Micro Milling Performance. Procedia CIRP 46: 352\u0026ndash;355. https://doi.org/10.1016/j.procir.2016.04.004\u003c/li\u003e\n\u003cli\u003eZeilmann R, Ost C, Fontanive F (2018) Characterization of edge preparation processes and the impact on surface integrity after milling of AISI P20 steel. Journal of the Brazilian Society of Mechanical Sciences and Engineering 40: 421. https://doi.org/10.1007/s40430-018-1338-7(0123456789().,-volV)(0123456789().,-volV)\u003c/li\u003e\n\u003cli\u003eHronek O, Zetek M, Bak\u0026scaron;a T, Ad\u0026aacute;mek P (2018) Influences of Cutting Edge Microgeometry on Durability when Milling ISO S Material. Manufacturing Technology 18: 394-399. https://doi.org/10.21062/ujep/111.2018/a/1213-2489/MT/18/3/394.\u003c/li\u003e\n\u003cli\u003eUhlmann E, Oberschmidt, Kuche Y, L\u0026ouml;wenstein A (2014) Cutting Edge Preparation of Micro Milling Tools. 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CIRP Annals - Manufacturing Technology 60: 73\u0026ndash;76. https://doi.org/10.1016/j.cirp.2011.03.098 \u003c/li\u003e\n\u003cli\u003eDenkena B, K\u0026ouml;hler J, Rehe M (2012) Influence of the honed cutting edge on tool wear and surface integrity in slot milling of 42CrMo4 steel. Procedia CIRP 1: 190-195. https://doi.org/10.1016/j.procir.2012.04.033\u003c/li\u003e\n\u003cli\u003eDenkena B, De Leon L, K̈hler J (2009) Cutting edge preparation for cemented carbide milling tools. Advanced Materials Research 76\u0026ndash;78: 597\u0026ndash;602. https://doi.org/10.4028/www.scientific.net/AMR.76-78.597\u003c/li\u003e\n\u003cli\u003eNardy M, Souza J, Santos S, Alves M, Ribeiro M, Antonialli A, Ventura C (2024) Surface finish and edge preparation of Al2O3\u0026thinsp;+\u0026thinsp;MgO cutting inserts by grinding and their application in hard turning. The International Journal of Advanced Manufacturing Technology 134: 677-689. https://doi.org/10.1007/s00170-024-14172-9\u003c/li\u003e\n\u003cli\u003eİrsel G, G\u0026uuml;zey B, Kara B (2022) Effect of heat-treatment temperature on the mechanical and microstructural properties of AISI 4140 steel. International Scientific Conference UNITECH 2022 Gabrovo 18-19: 93-100. https://doi.org/10.62853/BSUC2659\u003c/li\u003e\n\u003cli\u003eBarbosa M, Hassui A, De Oliveira P (2021) Effect of cutting parameters and cutting edge preparation on milling of VP20TS steel. International Journal of Advanced Manufacturing Technology 116: 2929\u0026ndash;2942. https://doi.org/10.1007/s00170-021-07654-7\u003c/li\u003e\n\u003c/ol\u003e"}],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":true,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":false,"highlight":"","institution":"","isAcceptedByJournal":true,"isAuthorSuppliedPdf":false,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":false,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"the-international-journal-of-advanced-manufacturing-technology","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jamt","sideBox":"Learn more about [The International Journal of Advanced Manufacturing Technology](https://www.springer.com/journal/170)","snPcode":"170","submissionUrl":"https://submission.nature.com/new-submission/170/3","title":"The International Journal of Advanced Manufacturing Technology","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false},"keywords":"milling, drag finishing, cutting edge, tool wear, abrasive media, AISI P20, SAE 4140","lastPublishedDoi":"10.21203/rs.3.rs-7574233/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-7574233/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eCutting edge preparation by drag finishing is used to refine microgeometry and extend tool life, especially when machining difficult-to-cut materials. This study investigates the influence of different abrasive media in drag finishing on the cutting edge microgeometry and wear behavior of cemented carbide end mills during milling of two steels, AISI P20 and SAE 4140. The objective is to understand the effects of abrasive media and contribute to the development of alternative solutions. The results showed that, in general, tools with edge preparation exhibit longer tool life compared to unprepared (sharpened) tools. The alternative ZR medium proposed in this work proved to be a viable option for the drag finishing process.\u003c/p\u003e","manuscriptTitle":"Effect of Cutting Edge Preparation by Drag Finishing on the Tool Wear in Milling of Steel","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2025-09-22 07:21:26","doi":"10.21203/rs.3.rs-7574233/v1","editorialEvents":[{"type":"communityComments","content":0},{"type":"reviewerAgreed","content":"","date":"2025-09-28T21:48:15+00:00","index":0,"fulltext":""},{"type":"reviewersInvited","content":"","date":"2025-09-13T12:50:15+00:00","index":"","fulltext":""},{"type":"editorAssigned","content":"","date":"2025-09-13T04:01:02+00:00","index":"","fulltext":""},{"type":"submitted","content":"The International Journal of Advanced Manufacturing Technology","date":"2025-09-11T18:21:15+00:00","index":"","fulltext":""}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"the-international-journal-of-advanced-manufacturing-technology","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jamt","sideBox":"Learn more about [The International Journal of Advanced Manufacturing Technology](https://www.springer.com/journal/170)","snPcode":"170","submissionUrl":"https://submission.nature.com/new-submission/170/3","title":"The International Journal of Advanced Manufacturing Technology","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false}}],"origin":"","ownerIdentity":"72ede912-5b9e-4161-b94f-18574464f28d","owner":[],"postedDate":"September 22nd, 2025","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"published-in-journal","subjectAreas":[],"tags":[],"updatedAt":"2026-03-02T16:07:01+00:00","versionOfRecord":{"articleIdentity":"rs-7574233","link":"https://doi.org/10.1007/s00170-025-17307-8","journal":{"identity":"the-international-journal-of-advanced-manufacturing-technology","isVorOnly":false,"title":"The International Journal of Advanced Manufacturing Technology"},"publishedOn":"2026-02-23 15:57:57","publishedOnDateReadable":"February 23rd, 2026"},"versionCreatedAt":"2025-09-22 07:21:26","video":"","vorDoi":"10.1007/s00170-025-17307-8","vorDoiUrl":"https://doi.org/10.1007/s00170-025-17307-8","workflowStages":[]},"version":"v1","identity":"rs-7574233","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-7574233","identity":"rs-7574233","version":["v1"]},"buildId":"8U1c8b4HqxoKbykW_rLl7","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}