Abstract
The phenomenon of tool wear strongly affects the efficiency of machining and the quality of machined products. The experimental approach to investigate tool wear requires several time consuming tests. Finite Element Methods (FEM) can be utilized to predict tool wear and tool life as function of process parameters and tool geometry. The commercial software for Finite Element Analysis (FEA) are limited by the impossibility to update the geometry of the worn tool. This research utilizes a self-released subroutine in order to modify the tool geometry in DEFORM 3D simulations by considering the volume reduction of the tool. The model was validated with experimental data obtained by drilling tests on Inconel 718 using conventional metal working fluids (MWF). The correct profile of the simulated worn tool was individuated by comparing the prediction of the simulation with the real tool geometry. The FEM simulation allowed to predict how torque changes during the tool life. In a predictive maintenance perspective, the model can be implemented to optimize the tools replacement.
Highlights
Nickel-chromium based superalloys, and in particular Inconel 718, are widely used in high temperature and extremely corrosive environments, such as jet engines parts, gas turbine components, and rocket motors in the aerospace industry, due to their ability to maintain proper mechanical characteristics in extreme conditions [1]
When drilling is considered, due to its internal machining nature and to the higher difficulty of the chip to be removed from the cutting zone, stronger mechanical and thermal loads on tool and workpiece are generated if compared with external machining [7], making the tool wear control more prominent
The validation of the model has been performed by the comparison of simulation results with the experimental data obtained by drilling tests of Inconel 718 with conventional metal working fluids (MWF) lubrication [11]
Summary
Nickel-chromium based superalloys, and in particular Inconel 718, are widely used in high temperature and extremely corrosive environments, such as jet engines parts, gas turbine components, and rocket motors in the aerospace industry, due to their ability to maintain proper mechanical characteristics in extreme conditions [1] The retain of these properties, combined with low thermal conductivity, high chemical affinity with cutting tool materials, and the presence of abrasive carbide particles, makes Inconel 718 a difficult-to-cut material, and it brings to a very pronounced tool wear [2,3]. The evolution of tool wear can be assessed by means of several experimental tests, but these are expensive and time consuming [8] To overcome this costly approach, Finite Element Methods (FEM) can be utilized. Hconv strongly depends on the cutting fluid proprieties and temperature and it can be experimentally determined
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