2D FEM Estimate of Tool Wear in Hard Cutting Operation: Extractive of Interrelated Parameters and Tool Wear Simulation Result

Abstract

Tool wear plays an important part during cutting process, and wear loss has a close relationship with cutting condition, which affects machined surface mostly. In order to accomplish tool wear prediction in way of FEM, based on founding of cutting model under steady state, interrelated parameters needed for tool wear prediction, such as cutting temperature, contact pressure and raletive sliding velocity are extracted. By compiling Python subprogram and using Abaqus tool in hard cutting process PCBN tool wear is predicted, which provide foundation for optimizing cutting condition.

Effect of tool flank wear on formation and prediction of tool flank rolling angle using finite element method

“…In certain FE studies on tool wear, the Usui model has been revised, and a new model has been proposed for different machining conditions. Yue et al 17 predicted the tool wear of a polycrystalline cubic boron nitride tool using the FE method, extracted the state variables obtained by a 2D cutting FE simulation, and proposed a relationship between the relative slip rate and node velocity. Considering that in a milling operation, almost all cutting process variables or solutions in the cutting stage are related to the thickness of the cut and tool engagement angle, Xie et al 7 proposed a ''differential'' tool wear rate model that was applied to 2D FE simulations for predicting tool wear during milling operations.…”

Finite Element Analysis Of Influence Of Flank Wear Evolution On Forces In Orthogonal Cutting Of 42CrMo4 Steel

“…Taylor's model estimations are based on empirical trials for given set of cutting conditions. The application of FEA model in estimating flank and rake wear was first introduced by Usui [14] and continued in works of [15][16][17]. In their research wear was modeled as modification of tools geometry due to displacement of tool's nodes.…”