Prediction of Tool Wear Rate and Tool Wear during Dry Orthogonal Cutting of Inconel 718

Abstract

A new prediction method was proposed based on the positive feedback relationship between tool geometry and tool wear rate. Dry orthogonal cutting of Inconel 718 was used as a case study. Firstly, tool wear rate models and a tool wear prediction flowchart were proposed. Secondly, the evolution of the tool geometry during tool wear was analyzed considering the combined effect of tool crater wear and tool flank wear. Thirdly, the evolution of the cutting temperature, normal stress and tool–chip relative sliding velocity on the tool wear surface was studied, the evolution of the tool wear rate during tool wear was revealed. Finally, the evolution of the tool geometry and tool wear rate during tool wear were applied to the tool wear prediction method to accurately predict the tool wear. The prediction error of KT is less than 15% in comparison with the experimental results. The tool wear prediction method in this paper is helpful to improve the prediction accuracy of tool crater wear.