Development and implementation of crater and flank tool wear model for hard turning simulations

Cristian Cappellini,Andrea Abeni

doi:10.1007/s00170-022-08885-y

Cristian Cappellini, Andrea Abeni

Open Access

https://doi.org/10.1007/s00170-022-08885-y

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Abstract

This paper concerns the tool wear in hard turning of AISI 52100 hardened steel by means of PCBN tools. The purposes of this work are the development of a tool wear model and its implementation in a FEM-based procedure for predicting crater and flank wear progression during machining operations for studying the influence of tool wear on the process in terms of tool geometry modifications and stress variation on the tool. The developed tool wear model, able to update the geometry of the worn tool as a function of the wear rate, has been implemented in the utilized Deform 2D FEM software. This new analytical model differs from the already proposed methods of existing research, since it concerns both crater and flank wear evaluation. The validation of the model has been achieved by the comparison between experimental and simulated wear parameters. For doing this, an extended experimental campaign has been accomplished. The comparison results have shown good agreement. Once validated, the FEM strategy has been utilized for examining the influence of tool wear on the effective rake angle and the related tool stresses, individuating the excessive positive rake angle value as the final tool breakage mechanism.

Highlights

In the last years, the increasing request of high production rate, extreme flexibility and process automation, low cycle time, maintaining at the same time good quality of the manufactured part, and with a sustainable process has become a key factor for the manufacturing industry [1]
The aim of this work is to reduce this lack of applications by developing a methodology for simulating the wear of polycrystalline cubic boron nitride (PCBN) tools in hard turning of AISI 52100 steel
It is important to monitor the value of this angle since, due to their high hardness but low toughness, PCBN tools present extremely high resistance to compressive stresses but poor to tensile ones; the application of a negative rake angle is recommended to enhance resulting compressive stresses on them

Summary

Introduction

The increasing request of high production rate, extreme flexibility and process automation, low cycle time, maintaining at the same time good quality of the manufactured part, and with a sustainable process has become a key factor for the manufacturing industry [1]. Multiple hard turning operations can be implemented in a single setup, while this is not useful when applying conventional grinding, bringing to a reduction on process time up to 60% for hard turning [6]. This process is usually performed in dry condition, without the application of coolants and lubricants that after need to be exhausted, enhancing the deployment of this finishing process under a sustainability point of view [7]

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