Abstract
In the process of metal cutting, the anti-wear performance of the tool determines the life of the tool and affects the surface quality of the workpiece. The finite element simulation method can directly show the tool wear state and morphology, but due to the limitations of the simulation time and complex boundary conditions, it has not been commonly used in tool life prediction. Based on this, a tool wear model was established on the platform of a finite element simulation software for the cutting process of titanium alloy TC4 by end milling. The key technique is to embed different types of tool wear models into the finite element model in combination with the consequent development technology. The effectiveness of the tool wear model was validated by comparing the experimental results with the simulation results. At the same time, in order to quickly predict the tool life, an empirical prediction formula of tool wear was established, and the change course of tool wear under time change was obtained.
Highlights
With the continuous development of the manufacturing industry, the surface performance of parts is more and more demanding
With the improvement of computer hardware calculation speed and software simulation efficiency, the finite element simulation method can effectively simulate the course of tool wear by considering the characteristics of milling process such as depth of cut variation
In order to reveal the influence of cutting parameter on tool abrasion, Choudhury et al [1] first established the analytic model of tool abrasion for the lathe tool without coating and researched the influence of feed rate and main shaft’s rotating speed on tool abrasion
Summary
With the continuous development of the manufacturing industry, the surface performance of parts is more and more demanding. In the research on tool abrasion simulation in analytic method, scholars find the tool abrasion is influenced by the cutting parameter, geometrical parameter of tool, cutting edge form of tool, cooling method, lubrication method, etc. With regard to the influence of tool’s geometrical shape on tool abrasion, Denkena et al [3] obtained the service life graph of lathe tools with different cutting edges microstructure in experiment research method, and later Rathod et al [4] established a prediction model of the abrasion of lathe tool’s flank surface by considering the influence of rake angle and clearance angle on abrasion of lathe tool’s flank surface. Zhang et al [6], based on the energy consumption method, established the abrasion model of flank surface to research the influence of cutting force on tool abrasion. PC Wanigarathne et al [8] researched the influence of temperature on tool abrasion through experiment and established the coupling relationship between cutting temperature and cutting force in the cutting process
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