Simulation Of Tool Wear Research Articles

A review of tool wear estimation using theoretical analysis and numerical simulation technologies

A thorough understanding of the material removal process in cutting is essential in selecting the tool material and in design, and also in assuring consistent dimensional accuracy and surface integrity of the finished product. Tool wear in cutting process is produced by the contact and relative sliding between the cutting tool and the workpiece, and between the cutting tool and the chip under the extreme conditions of cutting area. This paper presents the information on development of study on theoretical analysis and numerical simulation of tool wear in all over the world. Hidden Markov models (HMMs) were introduced to estimate tool wear in cutting, which are strongly influenced by the cutting temperature, contact stresses, and relative strains at the interface. Finite element method (FEM) is a powerful tool to predict cutting process variables, which are difficult to obtain with experimental methods. The objective of this work focuses on the new development in predicting the tool wear evolution and tool life in orthogonal cutting with FEM simulations.

Investigations on model-based simulation of tool wear with carbide tools in milling operation

This paper deals with tool wear in milling operation using carbide tools. The main purpose of this work is to define a model-based procedure for forecasting tool-wear progression during cutting operation by using machining simulation. Firstly, a multi-axis machining simulation algorithm is proposed based on DEXEL model and local area update method. NC milling machining process simulation software NCToolWearSim is realized by using Visual C++ and OpenGL. The developed process simulation software is used to simulate the cutting process. Secondly, tool-wear simulation algorithm in the machining process is presented with tool-wear model and machining simulation algorithm and is implemented into the machining simulation software NCToolWearSim in order to evaluate the tool wear and to update the tool geometry. The tool-wear value is estimated according to the established tool-wear model from experienced tool-wear data. Thus, tool-wear progression can be visualized in milling operation by using NCToolWearSim. Finally, experimental tests, performed milling integral wheel with carbide tools, were used to calibrate and validate the correctness of tool-wear simulation process based on the tool-wear model.

Investigation and FEM-based simulation of tool wear in turning operations with uncoated carbide tools

This paper deals with tool wear in turning using uncoated carbide tools. The main purpose of this work is to define a FEM-based procedure for forecasting tool wear progression during cutting operations. Deform 3D FEM software was used to simulate the cutting process and a suitable subroutine was implemented into the software in order to evaluate the tool wear and to update the tool geometry. The tool wear value is estimated according to well-known analytical models. Previous performed researches showed some problems in the correct identification of crater depth and position when using analytical tool wear models based only on abrasive or diffusive tool wear mechanisms. A new analytical tool wear model, taking into account the influence of both abrasive and diffusive tool wear mechanisms for overcoming these limits, was set-up and implemented by the authors. Experimental tests, performed turning AISI 1045 steel bars with ISO P40 uncoated tools, were used to calibrate and validate the FEM model. The comparison between FEM and experimental results showed good agreement. Once validated, the FEM model was used for analysing the influence of tool wear on the actual tool rake angle and on the tool stresses.

Predicted Rake Face Wear of PCBN Cutting Tools in High-Speed Precision Hard Cutting

PCBN cutting tool’s wear in high speed precision reaches tool wear criterion will cause cutting force and cutting temperature increase clearly, chip color change or melt. Even vibration in cutting will influence dimension accuracy and surface quality of workpiece. It is very useful to establish model by FEM simulation of tool wear predicted. The influence of tool wear in cutting conditions will assurance of machining quality and efficiency, decreasing rate of product cost. PCBN cutting tool’s wear is simulated by FEM software Deform 2D, rake face wear state can be analysed by the influence of tools geometric parameters and cutting parameters tool wear.

Finite element simulation of tool wear in turning of Inconel 718(Advanced machining technology)

In machining of nickel based superalloys, such as Inconel 718, tool wear is a major problem. Enhanced knowledge of the tool wear mechanism and capability to predict tool wear are of great importance. The objective with this paper is to investigate if an empirical wear model can describe the flank and crater wear of uncoated cemented carbide tool in a turning operation of Inconel 718. This empirical model has been implemented in a commercial FE-code and experimental trials have been conducted in order to obtain parameters of the empirical wear model and for validation. The wear rate volume at the flank and rake face as well as the cutting edge radius was measured with white light interferometry. FE-simulations were performed to calculate the wear rate at different cutting speeds. Results and comparison between experiments and simulation are presented in the paper.

Real-time Tool Wear Compensation in Milling EDM

Accurate machining by milling EDM (i.e. CNC contouring EDM with a rotating cylindrical or tubular electrode) necessitates compensation of the tool electrode wear. Existing anticipated wear compensation is based on off-line tool wear simulation prior to machining. This can be combined with corrections based on periodical measurements of tool length during machining. Anticipated wear compensation involves an important restriction: an exact model of the blank geometry must be available in order to perform the tool wear simulation. This paper presents a new method of wear compensation. On-line estimation of tool wear is used for combining anticipated compensation with real-time compensation. This extends the scope of milling EDM to the machining of blanks of which the exact shape is not known in advance.

How TiN coatings improve the performance of high speed steel cutting tools

TiN coatings deposited onto high speed steel (HSS) by physical vapour deposition have successfully been used in metal cutting applications for a number of years. Many papers have been presented which all show that TiN coatings often yield decreased wear rates and, usually, reduced friction coefficients. Although different theories are proposed in the literature (hardness theory, diffusion barrier theory, thermal barrier theory, reduced friction theory etc.), most papers have not dealt with the question of how and why TiN coatings modify the performance of HSS cutting tools. The present paper contributes to the answer of this question by (1) organizing published information about significant mechanical and chemical properties of TiN and (2) closely discussing different proposed theories and making comparisons with results from the broad spectrum of experiments (tool wear simulation testing, scratch testing in a scanning electron microscope, particle erosion testing, chip formation studies, metal cutting etc.) performed by the authors. A unique combination of sufficient adhesion to the substrate, high hot hardness, high wear resistance and an ability to improve the contact conditions at the cutting edge is concluded to be the answer. The complex interrelationships encompassed by this explanation are displayed in a flowchart. The thermal barrier function and the relatively low sliding friction coefficient of TiN are believed to be of minor importance.

Evaluation of some new cast hot-work die steels using simulation wear test

A wear-test programme carried out using a newly developed hot-work tool-wear simulation technique is described. Recently developed cast die steels containing coarse carbide dispersions have been assessed by comparison with orthodox hotwork steels. The new materials showed favourable wear properties under hotworking conditions. The relative wear resistances obtained for the materials Show good agreement with the results of previous hot-forging wear tests. Qualitative results from associated wear-surface observations and tool-workpiece compatibility studies are discussed to highlight the role of the technique in the overall assessment of a new tool material.