Pseudo analytical modelling of flank wear for coated/micro blasted cemented carbide cutting tools

Abstract

Machining of difficult to cut material leads to excessive amount of tool wear owing to dynamic nature of stresses. The amount of tool wear affects the machinability as well as tolerances during the cutting operation. Thus, monitoring of the flank wear is necessary under sustainable cutting environment. However, such monitoring in industrial and practical applications is a tedious task. The current study focuses on development of pseudo analytical model to predict the wear behaviour during the machining operation for the coated as well as surface modified (coated/micro blasted) tools. The model is possibly the first of its kind which incorporates the hardness of the coating, workflow stress and forces acting on the tool, while predicting the tool wear values. The developed model was calibrated and validated experimentally during the turning of Nimonic C 263 using AlTiN coated tools (treated and untreated) at varying cutting conditions. During the analysis it was found that the experimental results were very much in agreement with predicted values of the flank wear, and the flank wear progression also followed the similar pattern as that of the later.