An FEM-based approach for tool wear estimation in machining

Malakizadi, Amir; Gruber, Hans; Sadik, Ibrahim; Nyborg, Lars

doi:10.1016/j.wear.2016.08.007

Cited by 88 publications

(33 citation statements)

References 49 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The velocity distribution was calculated using the relative strain history distribution, ε t(i) − ε t(i-1) , divided by the stable simulated time increment, t S , and multiplied with the corresponding distance travelled, d (i−1) , as shown in Equation (6). This approach will eliminate any instability as observed here as well by Malakizadi [16]. Figure 16.…”

Section: Figure 15mentioning

confidence: 65%

“…Therefore, cutting speed was used in the wear rate calculations instead of sliding velocity. Malakizadi [16] also made similar observation regarding the instability and used cutting speed instead of sliding velocity.…”

Section: Finite Element Simulationmentioning

confidence: 76%

“…As the result, the sliding velocity equivalent to cutting speed magnitude was used in the wear rate model instead of simulated sliding velocity. Malakizadi [16] observed similar instability in the sliding velocity and used cutting speed instead of sliding velocity.…”

Section: Recommendation For Improvement In Wear Rate Estimation Durinmentioning

confidence: 86%

“…Calculating the displacement rate of each node along the tool-workpiece interface highly relies on the state of contact simulation, which is very complex in metal cutting. The complexity generally resulted in uncertainties in the simulated process variables such as sliding velocity which could lead to errors in nodal displacement calculation and consequently irregularity on updated worn geometry [16]. To overcome this issue, Malakizadi et al [17] and Hosseinkhani and Ng [18] developed methodologies to determine the rate of tool material loss on the flank face from average values of interface temperature and contact pressure instead of calculating the individual nodal displacement rates.…”

Section: Introductionmentioning

confidence: 99%

See 3 more Smart Citations

A Unique Methodology for Tool Life Prediction in Machining

Hosseinkhani

2020

JMMP

View full text Add to dashboard Cite

In this paper, a unique approach for estimating tool life using a hybrid finite element method coupled with empirical wear rate equation is presented. In the proposed approach, the computational time was significantly reduced when compared to nodal movement technique. However, to adopt such an approach, the angle between tool's rake and flank faces must be constant through the process and at least two cutting experiments need to be performed for empirical model calibration. It is also important to predict the sliding velocity along the tool/flank face interface accurately when using Usui's model to predict the tool wear rate. Model validations showed that when the sliding velocity was assumed to be equivalent to the cutting speed, poor agreement between the predicted and measured wear rate and tool life was observed, especially at low cutting speed. Furthermore, a new empirical model to predict tool wear rate in the initial or break-in period as a function of Von Mises stress field was developed. Experimental validation shows that the newly developed model substantially improved the initial tool wear rate in terms of trend and magnitude.

show abstract

Section: Figure 15mentioning

confidence: 65%

Section: Finite Element Simulationmentioning

confidence: 76%

Section: Recommendation For Improvement In Wear Rate Estimation Durinmentioning

confidence: 86%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

A Unique Methodology for Tool Life Prediction in Machining

Hosseinkhani

2020

JMMP

View full text Add to dashboard Cite

show abstract

“…Due to its significant impact on many process characteristics, the understanding and prediction of tool wear in metal cutting have drawn considerable attention [1][2][3][4][5]. The negative impact of tool wear on the surface properties of machined components necessitates a timely change of a cutting tool before a critical level of wear has been reached [6].…”

Section: Introductionmentioning

confidence: 99%

Tool wear by dissolution during machining of alloy 718 and Waspaloy: a comparative study using diffusion couples

Hoier

Surreddi

Klement

2019

Int J Adv Manuf Technol

View full text Add to dashboard Cite

The wear of metal cutting tools is known to take place by the combined and simultaneous effects of several wear mechanisms. Knowledge of the relative contribution of the individual wear mechanisms is required to understand and predict the tool wear during cutting different workpiece materials and alloys. It has been shown previously that machining two heat resistant superalloys, alloy 718 and Waspaloy, leads to distinctively different tool wears. Even though the subject has been addressed in various studies, there are still open questions regarding the underlying reasons for the differing tool wear rates. In particular, the relative contributions of diffusion/dissolution when machining the two alloys have not been addressed so far. Therefore, a qualitative comparison of the chemical interaction between the tool material and the two superalloys was made by using diffusion couple tests. The aim was to mimic the high temperatures and intimate contact between workpiece and tool material at the tool rake and flank faces during cutting under controlled and static conditions. The obtained results suggest that it is unlikely that differences in flank wear rate when machining the two superalloys are caused by significantly varying magnitudes of tool atoms dissolving into the respective workpiece. Analysis of the tool/superalloy interfaces in the diffusion couples revealed diffusion-affected zones of similar size for both tested superalloys. Increasing test temperature led to enhanced interdiffusion which suggests an increase in tool wear by diffusion/dissolution for higher cutting temperature. For alloy 718, the higher test temperature also led to depletion of carbon together with formation of tungsten within the tool in close vicinity to the interface with the superalloy.

show abstract

Cutting forces and crater wear prediction in orthogonal cutting using two approaches of finite element modeling

Soliman

Shash

El-Hossainy

et al. 2020

Engineering Reports

View full text Add to dashboard Cite

This work deals with plane strain finite element modeling for orthogonal cutting process of carbon steel. The experimental work conducted on a center lathe machine using carbide tools. The main objective was to simulate the cutting process by applying finite element method using computer software (Abaqus/CAE) to predict the cutting forces and crater wear. A comparative study was held between two modeling approaches; Lagrangian approach and Arbitrary Lagrangian-Eulerian (ALE) approach in terms of force prediction, reading stability and chip form. The results demonstrate that ALE model is more accurate and stable than Lagrangian model, as well ALE chip form is smoother and more reliable. Johnson-Cook (J-C) models were utilized to define the plastic and damage properties for the tool and workpiece materials in the finite element program. Finally, this work adopted a methodology to predict crater wear experimentally by using profilometer device. On the other side, the crater wear was predicted from simulation by measuring the contact pressure on tool face. The agreement between the simulation and experimental wear results proves that the ALE model is capable to predict tool wear.

show abstract

An FEM-based approach for tool wear estimation in machining

Cited by 88 publications

References 49 publications

A Unique Methodology for Tool Life Prediction in Machining

A Unique Methodology for Tool Life Prediction in Machining

Tool wear by dissolution during machining of alloy 718 and Waspaloy: a comparative study using diffusion couples

Cutting forces and crater wear prediction in orthogonal cutting using two approaches of finite element modeling

Contact Info

Product

Resources

About