Modeling and Analysis of Tool Wear Based on Cutting Force and Chip-Tool Interface Temperatures in Turning

Abstract

The aim of the present work is to develop a reliable method to predict tool wear precisely in a turning process by developing a mathematical model and comparing it with experimental results. Some important factors like cutting (chip-tool) interface temperature and three components of cutting forces as input variables and tool wear rate as an output variable have been used to develop the mathematical models. A set of experiments were performed on a commercial lathe without coolant. The experimental results show that there is an increase in three directional components of the cutting forces with increase in tool wear rate. Among the three components of cutting forces measured, the main cutting force (Thrust force) is the largest one while the radial force is the smallest. However, when the tool insert begins to fail, all the three cutting forces and chip-tool interface temperature increases sharply. The radial force was also found to be slightly larger than the feed force, when tool begins to fail. The mathematical models were solved by MATLAB software. To take into considerations these wears also, use of machining ratio as tool life criterion has been suggested.