Experimental support for a model-based prediction of tool wear

Wong, Tim K.; Kim, W.; Kwon, Patrick

doi:10.1016/j.wear.2004.03.010

Cited by 56 publications

(23 citation statements)

References 17 publications

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“…Rabinowicz [19] developed an empirical wear volume-loss equation in terms of normal load, sliding distance, the average roughness angle of the abrasive particle, and the ratio of the hardness of the tool and the abrasive particle under the threebody condition using a lapping process with the abrasives trapped between two sliding surfaces. This model can be extended to simulate flank wear volume due to three-body abrasion during turning of hardened steel by incorporating material hot hardness data and can be written as [12]:…”

Section: Abrasive Wear Modelmentioning

confidence: 99%

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Predictive modeling for flank wear progression of coated carbide tool in turning hardened steel under practical machining conditions

Chinchanikar

Choudhury

2014

Int J Adv Manuf Technol

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Growing needs for economical and environmental friendly manufacturing processes have increased usage of coated carbide tools in dry and high-speed machining of hardened steel. However, most undesirable characteristic of the machining process is tool wear; especially the flank wear, which adversely affects the dimensional accuracy and product quality. Therefore, prediction of flank wear progression will be extremely valuable. In the present study, a flank wear rate model is developed incorporating abrasion, adhesion, and diffusion as dominant wear mechanisms. Given the cutting conditions, tool geometry, and workpiece and cutting tool material properties, the model predicts flank wear progression with machining time. Developed model is calibrated and experimentally validated in turning of hardened AISI 4340 steel at different levels of hardness using chemical vapor deposition (CVD)-applied multilayer TiCN/Al 2 O 3 /TiN-coated carbide tool under practical 3-D machining conditions. As predicted results generally agree well with the experimental observations, proposed model could be helpful to predict the flank wear progression and hence to support the optimization studies within the domain of the cutting parameters.

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Section: Abrasive Wear Modelmentioning

confidence: 99%

“…Wong et al [12] suggested comprehensive equations for flank and crater wear. However, the developed equations overpredicted the results, especially at higher cutting speeds.…”

Section: Introductionmentioning

confidence: 99%

Predictive modeling for flank wear progression of coated carbide tool in turning hardened steel under practical machining conditions

Chinchanikar

Choudhury

2014

Int J Adv Manuf Technol

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“…The absence of craters in rake surface may be explained because of the tendency of WC/Co grades of cemented carbide to react with the work-piece to form a TiC layer. According to Hartung and Kramer [21] the presence of this layer eliminates the sliding between chip and tool, thus maximising the crater wear resistance [22]. The wear will be limited by the diffusion rate of the tool constituents through this layer.…”

Section: Final Wearmentioning

confidence: 99%

Dry drilling of alloy Ti–6Al–4V

Cantero

Tardío

Canteli

et al. 2005

International Journal of Machine Tools and Manufacture

181

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This work is focused on the combined study of the evolution of tool wear, quality of machined holes and surface integrity of work-piece, in the dry drilling of alloy Ti-6Al-4V. Tool wear was studied with optical microscope and SEM-EDS techniques. The quality of machined holes was estimated in terms of geometrical accuracy and burr formation. Surface integrity involves the study of surface roughness, metallurgical alterations and microhardness tests. The end of tool life was reached because of catastrophic failure of the drill, but no significant progressive wear in cutting zone was observed previously. High hole quality was observed even near tool catastrophic failure, evaluated from the point of view of dimensions, surface roughness and burr height. However, microhardness measurements and SEM-EDS analysis of work-piece showed important microstructural changes related with a loss of mechanical properties. Depending on the application of the machined component, the state of the work-piece could be more restrictive than the tool wear, and the end of tool life should be established from the point of view of controlled damage in a work-piece.

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“…The wear on the flank is chosen mainly because the flank wear is predominantly an abrasion phenomenon, evident by the presence of scoring marks on the wear surface [4,6,7]. This paper shows a feasible explanation of how, at the beginning of the cutting process, hard and round particles can cut in the cutting tool material.…”

Section: Wear Mechanismsmentioning

confidence: 99%

On the mechanism of two-body abrasive wear in turning “the spin-split theory”

Svenningsson

2017

Int J Adv Manuf Technol

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This approach regarding metal cutting in steel reveals the likely mechanisms behind a two-body abrasive wear. The theory is based on the assumption that ceramic hard inclusions in the secondary and tertiary cutting zones cannot to any significant extent be deformed plastically. The inclusions, in most cases roundish bullet-type particles, are forced to rotate or break due to the large shear stresses in the cutting zones. A bullet-type particle cannot efficiently cut or wear on the cutting tool rake and tool flank, but when the particle is torn apart, efficient sharp edges are created. Those edges are then, due to the elongation and contraction of the matrix material, pressed out towards the cutting tool, where they, while still rotating, cut until their cutting geometry become less favourable and at that point break into small fragments, which together with the matrix material are welded on the tool clearance and the tool rake faces. Those deposits with particle remnants and chips from the cutting tool contain 30-40% of ceramic material. The rest is matrix material from the workpiece. The understanding of this mechanism opens new ways to improve cutting materials, both coating and substrate, and the workpiece materials.

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Experimental support for a model-based prediction of tool wear

Cited by 56 publications

References 17 publications

Predictive modeling for flank wear progression of coated carbide tool in turning hardened steel under practical machining conditions

Predictive modeling for flank wear progression of coated carbide tool in turning hardened steel under practical machining conditions

Dry drilling of alloy Ti–6Al–4V

On the mechanism of two-body abrasive wear in turning “the spin-split theory”

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