A model of non-linear cumulative damage to tools at changing cutting speeds

Damage to cutting tools is in most cases non-linear. In cutting at a constant speed, the traditional Taylor formula can be applied to determine tool life. However, it is frequently the case that the given tool is used at various cutting speeds until it becomes completely worn down, thereby rendering this formula unusable. In cutting at changing or alternating speeds, the generalised form of the Taylor formula provides a solution, which could be derived from the non-linear damage to the tool. Although damage to tools is mostly non-linear, it was proven that the linear model ∑Δti/Ti = 1 can serve well. By applying this formula, an equivalent cutting speed can be determined that can also be handled by means of the traditional Taylor formula, and in this way, tool life equations may even be determined under production conditions. Cutting experiments were conducted with an uncoated carbide tool and AISI1045 steel.

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