Wear modelling in mild steel orthogonal cutting when using uncoated carbide tools

Abstract Wear prediction in machining has been recently studied by FEM although the use of numerical methods for such applications is still a very challenging research issue. In fact, wear phenomenon involves many aspects related to process mechanics which require a very accurate modelling. In other words, only a very punctual code set-up can help the researchers in order to obtain consistent results in FE analysis. The high relative velocity between chip and tool requires effective material models as well as friction modelling at the interface. Moreover the prediction of temperature distribution is another critical task; in the paper some different procedures are discussed. Subsequently a wear model is presented and calibrated in order to obtain a suitable tool to be implemented in a FE code with the aim to describe the wear evolution during the simulation process. A proper designed experimental campaign supplied some reference data for model set-up and verify in the practical application. All these aspects are carefully discussed in the paper.

[1]  Taylan Altan,et al.  Estimation of tool wear in orthogonal cutting using the finite element analysis , 2004 .

[2]  V. Astakhov.  Metal Cutting Mechanics , 1998 .

[3]  David Dornfeld,et al.  A self-organizing approach to the prediction and detection of tool wear , 1998 .

[4]  R. J. Kuo,et al.  Intelligent tool wear estimation system through artificial neural networks and fuzzy modeling , 1998, Artif. Intell. Eng..

[5]  Thomas Childs,et al.  Metal Machining: Theory and Applications , 2000 .

[6]  L. J. Yang.  Wear coefficient of tungsten carbide against hot-work tool steel disc with two different pin settings , 2004 .

[7]  Weiguo Gong,et al.  An active method of monitoring tool wear states by impact diagnostic excitation , 2004 .

[8]  Mingyuan Chen,et al.  Relationship between tool flank wear area and component forces in single point turning , 2002 .

[9]  Fabrizio Micari,et al.  A simple inverse procedure to determine heat flux on the tool in orthogonal cutting , 2006 .

[10]  T. I. El-Wardany,et al.  PHYSICS-BASED SIMULATION OF HIGH SPEED MACHINING , 2002 .

[11]  M. C. Shaw.  Metal Cutting Principles , 1960 .

[12]  Taylan Altan,et al.  ESTIMATION OF TOOL WEAR OF CARBIDE TOOL IN ORTHOGONAL CUTTING USING FEM SIMULATION , 2002 .

[13]  Viktor P. Astakhov,et al.  The assessment of cutting tool wear , 2004 .

[14]  S. R. S. Kalpakjian.  Manufacturing Processes for Engineering Materials , 1984 .

[15]  Patrick Kwon,et al.  Experimental support for a model-based prediction of tool wear , 2004 .

[17]  M. C. Shaw,et al.  Mechanics of Machining: An Analytical Approach to Assessing Machinability , 1989 .

[18]  Mohammed Nouari,et al.  Experimental verification of a diffusion tool wear model using a 42CrMo4 steel with an uncoated cemented tungsten carbide at various cutting speeds , 2005 .

[19]  S. K. Choudhury,et al.  Tool wear prediction in turning , 2004 .

[20]  Elisabetta Ceretti,et al.  Basic Aspects and Modeling of Friction in Cutting , 2001 .

[21]  A. Molinari,et al.  Modeling of tool wear by diffusion in metal cutting , 2002 .

[22]  L. J. Yang.  Pin-on-disc wear testing of tungsten carbide with a new moving pin technique , 1999 .