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Modelling and Simulation of Tool Wear During the Cutting Process
F. Salvatorea, S. Saad, H. Hamd
Abstract
Experimental and analytic methods are still the main ways to investigate different cutting tool wear types. Numerous developments
of numerical methods and simulations, associated to the existence of more and more powerful computer make possible tool wear
studies using FEM. The main purpose of this work is to present a new approach to predict tool wear progression during cutting
operation. In particular, an energy approach, linking the tool wear volume with the energy dissipated by friction is used. In addition,
the interaction between residual stresses induced by cutting and the variation of tool geometry due to wear’s mechanisms is
investigated.
In order to carry out this study, it is presented the experimental measurements of the wear of the tool, in particular the lost volume
during the cut. Numerical simulation of orthogonal cutting operation using the commercial FEM code ABAQUS/Explicit is employed.
Conclusion
In the presented paper, tool wear modeling has
developed as a result from the energy dissipation on the
contact zone. This approach leads to implementing a
damage law in the tool material. The method of
elimination of nodes of the tool is used when the latter
reaches the value of a defined maximum energy fields.
The first results of the tool wear delivered by FEM
energetic approach seems like interesting. For sure, it is
necessary to complete the study with the setting of the
tool wear using fracture energy.
Afterwards, a section is devoted to the development
of a new method that allows us to significantly reduce
the computation time required to complete the
simulation. The approach high-lights the fact that the
computation time is generated by the complexity of
managing the contact between the chip and work piece.
This method presented in this paper keeps the history
of machining in the finished part and as a result, it is
possible to derive the residual stresses induced in the
part. This last aspect will be presented in a future paper.
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