Estimation of tool wear in orthogonal cutting using the finite element analysis

Journal of Materials Processing Technology

Volumn 146, Issue 1, 2004, Pages 82-91

  Yen, Yung Chang ^a   Söhner, Jörg ^b   Lilly, Blaine ^a   Altan, Taylan ^a  

^a OHIO STATE UNIVERSITY   (United States)

^b UNIVERSITY OF KARLSRUHE   (Germany)

Author keywords

Finite element method (FEM); Orthogonal cutting; Tool life; Tool wear; Wear mechanisms

Indexed keywords

CALIBRATION; COATINGS; COMPUTER SIMULATION; COOLANTS; CUTTING TOOLS; ERROR ANALYSIS; FINITE ELEMENT METHOD; FRICTION; OPTIMIZATION; STRESSES; WEAR OF MATERIALS;

ORTHOGONAL CUTTING; TOOL LIFE; TOOL WEAR; WEAR MECHANISMS;

METAL CUTTING;

EID: 0942277636     PISSN: 09240136     EISSN: None     Source Type: Journal    
DOI: 10.1016/S0924-0136(03)00847-1     Document Type: Article

References (27)

1. U. Walter, Einfluss des Kühlschmierstoffes beim Fräsen, Dissertation, Universität Karlsruhe (TH), Karlsruhe, Germany, 1998.
2. Strenkowski J.S., Carroll J.T. A finite element model of orthogonal cutting. ASME J. Eng. Ind. 107:1985;349-354.
3. Ceretti E., Fallböhmer P., Wu W.-T., Altan T. Application of 2D FEM to chip formation in orthogonal cutting. J. Mater. Process. Technol. 59:1996;169-181.
4. I.S. Jawahir, O.W. Dillon, Jr., A.K. Balaji, M. Redetzky, N. Fang, Predictive modeling of machining performance in turning operations, in: Proceedings of the CIRP International Workshop on Modeling of Machining Operations, Atlanta, GA, USA, May 19, 1998, pp. 161-176.
5. Özel T., Lucchi M., Rodriguez C., Altan T. Prediction of chip formation and cutting forces in flat end milling: comparison of process simulation with experiments. Trans. NAMRI/SME. XXVI:1998;231-236.
6. Shatla M., Yen Y.-C., Altan T. Tool-workpiece interface in orthogonal cutting - application of FEM modeling. Trans. NAMRI/SME. XXVIII:2000;173-178.
7. E.G. Hoffman, Fundamentals of Tool Design, 3rd ed., SME, Dearborn, MI, 1984, p. 83.
8. Jawahir I.S., Ghosh R., Fang X.D., Li P.X. An investigation of the effects of chip flow on tool-wear in machining with complex grooved tools. Wear. 184:1995;145-154.
9. P.L.B. Oxley, The Mechanics of Machining - An Analytical Approach to Assessing Machinability, Ellis Horwood, Chichester, 1989, p. 185.
10. Mathew P. Use of predicted cutting temperatures in determining tool performance. Int. J. Mach. Tools Manuf. 29(4):1989;481-497.
11. Molinari A., Nouari M. Modeling of tool wear by diffusion in metal cutting. Wear. 252:2002;135-149.
12. Usui E., Hirota A., Masuko M. Analytical prediction of three-dimensional cutting process. Part 3. Cutting temperature and crater wear of carbide tool. Trans. ASME. 100:1978;222-228.
13. H. Takeyama, T. Murata, Basic investigations on tool wear, Trans. ASME J. Eng. Ind. 85 (1963) 33-38.
14. Kitagawa T., Maekawa K., Shirakashi T., Usui E. Analytical prediction of flank wear of carbide tools in turning plain carbon steels. Part 1. Characteristic equation of flank wear. Bull. Jpn. Soc. Precis. Eng. 22(4):1988;263-269.
15. Kitagawa T., Maekawa K., Shirakashi T., Usui E. Analytical prediction of flank wear of carbide tools in turning plain carbon steels. Part 2. Prediction of flank wear. Bull. Jpn. Soc. Precis. Eng. 23(2):1989;126-134.
16. Smithey D.W., Kapoor S.G., DeVor R.E. A worn tool force model for three-dimensional cutting operations. Int. J. Mach. Tools Manuf. 40:2000;1929-1950.
17. Jawahir I.S., Ghosh R., Fang X.D., Li P.X. An investigation of the effects of chip flow on tool-wear in machining with complex grooved tools. Wear. 184:1995;145-154.
18. Chou Y.K., Evans C.J. Tool wear mechanism in continuous cutting of hardened tool steels. Wear. 212:1997;59-65.
19. Kato K. Wear in relation to friction - a review. Wear. 241:2000;151-157.
20. Shatla M., Yen Y.-C., Altan T. Tool-workpiece interface in orthogonal cutting - application of FEM modeling. Trans. NAMRI/SME. XXVIII:2000;173-178.
21. M. Shatla, Prediction of Forces, Stresses, Temperatures and Tool Wear in Metal Cutting, Ph.D. Dissertation, The Ohio State University, 1999.
22. Y.-C. Yen, J. Söhner, H. Weule, J. Schmidt, T. Altan, Estimation of tool wear in orthogonal cutting using FEM simulation, Machining Science Technology 6 (3) (2002) 467-486.
23. H.-W. Raedt, S. Hoppe, F. Klocke, 2D-FEM simulation of the orthogonal high speed cutting process, WZL, Aachen, in: Proceedings of the Fourth CIRP International Workshop on Modeling of Machining Operations, Delft, The Netherlands, August 17-18, 2001, pp. 117-124.
24. Müller B., Renz U. Development of a fast fiber-optic two-color pyrometer for the temperature measurement of surfaces with varying emissivities. Rev. Sci. Instr. Am. Instit. Phys. 72:2001;8.
25. R.W. Ivester, M. Kennedy, M. Davies, R. Stevenson, Assessment of Machining Models, Progress Report, Official contribution of NIST on the website http://www.nist.gov/amm/ , 2001.
26. ISO 3685 International Standard: Tool-Life Testing with Single-Point Turning Tools, 2nd ed., 1993, p. 12.
27. N. Chandrashekar, Y.-C. Yen, T. Altan, Comparison of Tool Wear Experimental Results of AISI-1045 between Orthogonal Tube Turning and Conventional Bar Turning ERC Technical Report: HPM/ERC/NSM-01-R-30, The Ohio State University, 2001.