Flank Wear Model of Cutting Tools Using Control Theory

A model of the flank wear of cutting tools is developed by using linear control theory. The flank wear is assumed to consist of a mechanically activated and a thermally activated component. The wear process is mathematicall y treated as a feedback process, whereby the progressive wear raises the cutting forces and temperature thereby increasing the thermally activated wear-rate, and contributes to the mechanically activated wear. A mathematical expression for the flank wear growth is derived and shown to be consistent with experimental results. The experimental data is fitted to the wear model for calculat­ ing the mechanical wear coefficient and activation energy for the thermally activated wear. The model yielded a new tool-life equation which is valid over a wider range of speed than Taylor tool-life equation.