FEM-DEM coupling simulations of the tool wear characteristics in prestressed machining superalloy

Abstract

Abstract. Due to the complicated contact loading at the tool-chip interface, ceramic tool wear in prestressed machining superalloy is rare difficult to evaluate only by experimental approaches. This study aims to develop a methodology to predict the tool wear evolution by using combined FEM and DEM numerical simulations. Firstly, a finite element model for prestressed cutting is established, subsequently a discrete element model to describe the toolchip behaviour is established based on the obtained boundary conditions by FEM simulations, finally, simulated results are experimentally validated. The predicted tool wear results show nice agreement with experiments, the simulation indicates that, within a certain range, higher cutting speed effectively results in slighter wear of Sialon ceramic tools, and deeper depth of cut leads to more serious tool wear.

Wear of carbide inserts with complex surface treatment when milling nickel alloy

“…Depending on machining conditions, one of these types of wear becomes predominant, although other ones may be presented as well. Experiments reveal that adhesion wear during machining [21,22] results from particles of material which are broken off the machined surface. These torn particles are transferred onto the surface of the tool and form lumps with a rather high hardness, which is promoted by a high contact temperature on the cutting tool surfaces caused by friction factors, and it is considerably higher than those of structural steels due to an intense adhesion contact.…”

Dynamic modeling of the turning process of slip-cast fused silica ceramics using the discrete element method

“…They illustrated that for rough bound abrasive grinding, by minimizing feed rate and depth of cut and maximizing spindle speed, the maximal depth of subsurface damage was minimized. More recently, Ruitao et al 27 utilized the DEM method to simulate ceramic tool wear in pre-stressed machining of superalloy GH4169. They simulated the effect of pre-stress, cutting depth, and cutting speed on tool wear.…”