Abstract
The present work aims at improving tool wear simulation in orthogonal turning operations by considering local wear properties at the scale of the coating. A multi-step procedure developed in previous studies is first employed to predict cutting tool wear by combining a pure thermal model to an Arbitrary-Lagrangian-Eulerian (ALE) thermomechanical sub-model in order to predict the thermomechanical loadings applied onto the tool. The tool geometry is updated by moving the tool nodes, taking into account the local contact pressure, sliding velocity and temperature. The key improvement of this paper is to implement a specific wear model for each of the coating layer and substrate depending on the current position of each node at the contact interface. A comparative study is performed between the homogenous wear equation and the improved multi-layer model. This work highlights that an adaptive wear rate calculation based on nodal position has to be considered to achieve an actual predictive model.
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