Finite Element Method Based Modeling for Tool Wear Prediction in Orthogonal Cutting Process

Abstract

Finite element method (FEM) plays vital role in simulation of many complex problems in fields such as machining, automotive, aerospace, etc. Tool wear is one of the machining problems that is essential in research due to its importance and its effect on product quality and cost. This paper shows the utilization of finite element method in modeling of two dimensional orthogonal cutting process to predict tool wear of uncoated tungsten carbide tool using Abaqus/CAE program. The simulation methodology included the implementation of Johnson-Cook (J-C) model to define the material behavior. Also, the adaptive meshing technique (ALE) is used in simulation the cutting process to combine the advantages of Lagrangian technique that is commonly used in solid mechanics analysis and Eulerian techniques that is commonly used in fluid mechanics analysis. The objective is to predict tool wear location on tool face by using finite element method and compare the results with the experimental work.