Physics-Based Simulations of Chip Flow over Micro-Textured Cutting Tool in Orthogonal Cutting of Alloy Steel

Kaushalendra V Patel,Krzysztof Jarosz,Tuğrul Özel

doi:10.3390/jmmp5030065

Abstract

Physics-based process simulations have the potential to allow virtual process design and the development of digital twins for smart machining applications. This paper presents 3D cutting simulations using the finite element method (FEM) and investigates the physical state variables that are fundamental to the reduction in cutting forces, friction, and tool wear when micro-textured cutting tools are employed. For this goal, textured cemented carbide cutting tool inserts are designed, fabricated, and tested in the orthogonal dry cutting of a nickel-chromium-molybdenum alloy steel. Cutting forces and friction coefficients are compared against the non-textured tool, revealing the effects of texture parameters. Chip flow over the textured tool surface and process variables at the chip-tool contact are investigated and compared. The results reveal the fundamental sources of such improvements. Archard’s wear rate as a composition of process variables is utilized to compare experimental and simulated wear on the textured cutting tools. The effects of texture and cutting conditions on tool wear and adhesion characteristics are further discussed on the simulation results with experimental comparisons. It was found that the results obtained from these simulations provide further fundamental insights about the micro-textured cutting tools.

Highlights

The Industry 4.0 and computerization have a significant impact on the machining industry, facilitating its development and evolution to meet new demands arising from increasing part complexity, quality requirements, and the increased demand for parts made from difficult-to-cut alloys
A digital twin for the cutting tool can be developed [3] where the role of the physics-based tool wear rate models, depending on the contact conditions, chip flow, temperature, and stress at the tool-chip interface, becomes even more valuable if such calculations can be integrated within the smart machining and digital shadow/digital twin framework
The crater wear on the tool rake face of the micro-textured area is compared against the cutting tools with no texture when the same distance of cut is used under all cutting conditions, as given in the charts of Figure 7

Summary

Introduction

The Industry 4.0 and computerization have a significant impact on the machining industry, facilitating its development and evolution to meet new demands arising from increasing part complexity, quality requirements, and the increased demand for parts made from difficult-to-cut alloys. Machine Learning algorithms can be further utilized here for a number of purposes, ranging from on-line process monitoring (be it in the aspect of machine health/performance or product quality), to process optimization to improve productivity/workpiece quality From this perspective, a digital twin for the cutting tool can be developed [3] where the role of the physics-based tool wear rate models, depending on the contact conditions, chip flow, temperature, and stress at the tool-chip interface, becomes even more valuable if such calculations can be integrated within the smart machining and digital shadow/digital twin framework. Microtextures applied on cutting tool faces reduce contact area and friction force at the chip-tool interface, improve anti-adhesion, flaking and crater wear resistance, reduce abrasive wear by captivating wear debris, enhance thermal transport, and enable the effective utilization of lubricants in cutting processes This introduction section will review the physics-based cutting tool wear and contact mechanisms to establish a background in the premise of micro-texture cutting tools

Objectives

Methods

Results

Conclusion