Abstract
Due to the complicated contact loading at the tool-chip interface, ceramic tool wear in prestressed machining superalloy is rare difficult to evaluate only by experimental approaches. This study aims to develop a methodology to predict the tool wear evolution by using combined FEM and DEM numerical simulations. Firstly, a finite element model for prestressed cutting is established, subsequently a discrete element model to describe the tool-chip behaviour is established based on the obtained boundary conditions by FEM simulations, finally, simulated results are experimentally validated. The predicted tool wear results show nice agreement with experiments, the simulation indicates that, within a certain range, higher cutting speed effectively results in slighter wear of Sialon ceramic tools, and deeper depth of cut leads to more serious tool wear.
Highlights
Nickel-based superalloys are widely utilized in industrial application due to their excellent performance, as a hardto-machine material there’s still a challenge to cut the alloy efficiently, prestressed cutting method has been validated as an efficacious way to control surface residual stress [1, 2], characteristics of superalloy induce severe thermo-mechanical loads at the tool-chip interface which still result in significant wear of the tool.Tool wear phenomena are complicate and experimental, analytical and numerical investigations are important keys to reveal the tool wear process and mechanism
The contact stress and contact length between tool and chip, temperature distribution of tool as well as speed of chip flow are obtained based on finite element method (FEM) simulations
The discrete element method (DEM) simulation results are shown in Figure.7 and Figure.8, the white curves refers to the detached particles, which are named cracks in the cutting process, it is convenient to analyze the concealed cracks of the tool, the tool’s crack produced in the rake face can be observed distinctly which has a certain distance to the tool tip, and it gradually extends to the inner layer until to the rear face, lamellar exfoliation is occurred on the tool tip
Summary
Nickel-based superalloys are widely utilized in industrial application due to their excellent performance, as a hardto-machine material there’s still a challenge to cut the alloy efficiently, prestressed cutting method has been validated as an efficacious way to control surface residual stress [1, 2], characteristics of superalloy induce severe thermo-mechanical loads at the tool-chip interface which still result in significant wear of the tool. Tool wear phenomena are complicate and experimental, analytical and numerical investigations are important keys to reveal the tool wear process and mechanism. Experimental studies are performed to investigate the tool wear in machining superalloy. Investigated the temperature and wear of ceramic tools in high-speed machining of Inconel 718, boundary wear has been observed as the main form of tool wear.
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