3D modeling of tool wear and optimization in hard turning considering the effects of tool cutting edge and nose radii

3D modeling of tool wear and optimization of hard turning have been performed in this study considering the tool geometry parameters, i.e., cutting edge and nose radii. Optimization is carried out using multiple objective and constraint, and it employs a meta-model that is developed using response surfaces based on radial basis functions. A 3D finite element model has been developed considering the tool geometry and is verified using force measurement during hard turning experiments on H-13. Chip formation simulations have been done using the coupled temperature displacement analysis based on explicit dynamics. The tool wear model is implemented using Usui’s model for adhesive wear. This model takes input from the steady-state chip formation analysis, and the contact nodes on the tool are repositioned according to the wear rate and time increment. The model is able to predict chip morphology, force components, tool wear, stress, and temperature distributions. The effects of cutting edge and nose radii on tool stresses, tool wear, and temperature have been discussed. For optimization search genetic algorithm, MOGA-II is selected which has been used to optimize tool temperature and material removal rate during hard turning. Optimize solutions suggest the selection of high to moderate cutting edge and nose radii, large feeds, and low to moderate cutting speeds.