Study on the effect of wear models in tool wear simulation using hybrid SPH-FEM method

Abstract

The prediction of the tool wear progression using numerical methods has been widely studied in recent years, and various wear models considering different wear mechanisms have been implemented in the simulation work. Typically, these wear models take the physical fields such as contact pressure, sliding velocity and temperature at the tool-workpiece interface into account and are applied either individually or in combinations into the wear simulation. However, how and to what extent the physical parameters in these models affect the generated wear profiles have not been explored in detail in the simulation. In this paper, the behaviors of several typical wear models are studied by simulating the tool wear of cutting Ti6Al4V using a hybrid SPH-FEM method. Considering different combinations of physical contact parameters in the wear model, the simulated wear progression is discussed, and the resulting worn tool geometry is qualitatively compared to the experimental result. Furthermore, insights into the calibration of wear models are proposed.