A Fracture Mechanics Approach to the Prediction of Tool Wear in Dry High Speed Machining of Aluminum Cast Alloys—Part 2: Model Calibration and Verification

2006 ◽  
Vol 129 (1) ◽  
pp. 31-39 ◽  
Author(s):  
Alexander Bardetsky ◽  
Helmi Attia ◽  
Mohamed Elbestawi
Keyword(s):  
Tool Wear ◽  
Automotive Industry ◽  
Model Calibration ◽  
High Speed ◽  
Cutting Tool ◽  
Tool Material ◽  
Cutting Conditions ◽  
High Speed Machining ◽  
Wear Model ◽  
Cast Alloys

Background. Aluminum alloys are extensively used in the automotive industry and their utilization continues to rise because of the environmental, safety and driving performance advantages. Experimental study has been carried out in this work to establish the effect of cutting conditions (speed, feed, and depth of cut) on the cutting forces and time variation of carbide tool wear data in high-speed machining (face milling) of Al–Si cast alloys that are commonly used in the automotive industry. Method and Approach. The experimental setup and force measurement system are described. The cutting test results are used to calibrate and validate the fracture mechanics-based tool wear model developed in part 1 of this work. The model calibration is conducted for two combinations of cutting speed and a feed rate, which represent a lower and upper limit of the range of cutting conditions. The calibrated model is then validated for a wide range of cutting conditions. This validation is performed by comparing the experimental tool wear data with the tool wear predicted by calibrated cutting tool wear model. Results and Conclusions. The maximum prediction error was found to be 14.5%, demonstrating the accuracy of the object oriented finite element (OOFE) modeling of the crack propagation process in the cobalt binder. It also demonstrates its capability in capturing the physics of the wear process. This is attributed to the fact that the OOF model incorporates the real microstructure of the tool material. The model can be readily extended to any microstructure of Al–Si workpiece and carbide cutting tool material.

A Fracture Mechanics Approach to the Prediction of Tool Wear in Dry High Speed Machining of Aluminum Cast Alloys: Part 2 — Model Calibration and Verification

Tribology ◽  
2005 ◽  
Author(s):  
Alexander Bardetsky ◽  
Helmi Attia ◽  
Mohamed Elbestawi
Keyword(s):  
Fracture Mechanics ◽  
Tool Wear ◽  
Model Calibration ◽  
High Speed ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
High Speed Machining ◽  
Wear Model ◽  
Wide Range ◽  
Cast Alloys

Experimental study has been carried out to establish the effect of cutting conditions (speed, feed, and depth of cut) on the cutting forces and time variation of carbide tool wear data in high-speed machining (face milling) of Al-Si cast alloys that are commonly used in the automotive industry. The experimental setup and force measurement system are described. The test results are used to calibrate and validate the fracture mechanics-based tool wear model developed in Part 1 of this work. The model calibration is conducted for two combinations of cutting speed and a feed rate, which represent a lower and upper limit of the range of cutting conditions. The calibrated model is then validated for a wide range of cutting conditions. This validation is performed by comparing the experimental tool wear data with the tool wear predicted by calibrated cutting tool wear model. The prediction errors were found to be less then 7%, demonstrating the accuracy of the object oriented finite element (OOFE) modeling of the crack propagation process in the cobalt binder. It also demonstrates its capability in capturing the physics of the wear process. This is attributed to the fact that the OOF model incorporates the real microstructure of the tool material.

A Fracture Mechanics Approach to the Prediction of Tool Wear in Dry High Speed Machining of Aluminum Cast Alloys: Part 1 — Model Development

Tribology ◽  
2005 ◽  
Author(s):  
Alexander Bardetsky ◽  
Helmi Attia ◽  
Mohamed Elbestawi
Keyword(s):  
Fracture Mechanics ◽  
Wear Rate ◽  
Tool Wear ◽  
Crack Propagation ◽  
High Speed ◽  
Cutting Tool ◽  
Fe Model ◽  
High Speed Machining ◽  
Aluminum Cast Alloys ◽  
Cast Alloys

The analysis of the mechanism of cutting tool wear in high speed machining of cast aluminum alloys is conducted in this research work. The result of analysis indicates that the interaction between the hard silicon constituencies of the alloy and the surface of the cutting tool is the most detrimental to tool life. The wear of the cutting tool in such interactions, governed by fatigue wear mechanism, is directly proportional to silicon content of the alloy, silicon grain size and to the tool’s loading conditions. In order to predict the tool wear in machining aluminum cast alloys, a new wear model is developed. The fracture mechanics approach in wear rate estimation is implemented in this model. As an input data for the tool wear modeling, the normal and tangential stresses, acting on the flank of cutting tool are used. The fracture mechanics analysis of the subsurface crack propagation in the cobalt binder of cemented carbide cutting tool material is performed using a finite element (FE) model of the tool-workpiece sliding contact. The real microstructure of cemented carbide is incorporated in the FE model of tool-workpiece contact, and elastic-plastic properties of cobalt, defined by continuum theory of crystal plasticity are introduced in the model by UMAT subroutine of the ABAQUS® FE software. The crack propagation rate, determined from FE modeling, is used then in the model of cutting tool wear, developed in this work. This model is capable to predict the wear rate of cutting tool, base on the microstructural characteristics of the cutting tool and workpiece material and the tool’s loading conditions. The model can be used for cutting tool life assessment and management in high speed machining of Al-Si alloys in an industrial setting.

scholarly journals A Hybrid Remaining Useful Life Prediction Method for Cutting Tool Considering the Wear State

2022 ◽  
Author(s):  
Yifan Li ◽  
Yongyong Xiang ◽  
Baisong Pan ◽  
Luojie Shi
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
Cutting Tool ◽  
Bayesian Framework ◽  
Remaining Useful Life ◽  
Physical Models ◽  
Data Driven ◽  
Support Vector ◽  
Wear Model ◽  
Useful Life

Abstract Accurate cutting tool remaining useful life (RUL) prediction is of significance to guarantee the cutting quality and minimize the production cost. Recently, physics-based and data-driven methods have been widely used in the tool RUL prediction. The physics-based approaches may not accurately describe the time-varying wear process due to a lack of knowledge for underlying physics and simplifications involved in physical models, while the data-driven methods may be easily affected by the quantity and quality of data. To overcome the drawbacks of these two approaches, a hybrid prognostics framework considering tool wear state is developed to achieve an accurate prediction. Firstly, the mapping relationship between the sensor signal and tool wear is established by support vector regression (SVR). Then, the tool wear statuses are recognized by support vector machine (SVM) and the results are put into a Bayesian framework as prior information. Thirdly, based on the constructed Bayesian framework, parameters of the tool wear model are updated iteratively by the sliding time window and particle filter algorithm. Finally, the tool wear state space and RUL can be predicted accordingly using the updating tool wear model. The validity of the proposed method is demonstrated by a high-speed machine tool experiment. The results show that the presented approach can effectively reduce the uncertainty of tool wear state estimation and improve the accuracy of RUL prediction.

Evaluation of Tool Wear Suppressive Ability of Lubricants Usein in Minimum Quantity Lubrication Application in High Speed Machining of Cast Aluminum Alloys

2005 ◽  
Author(s):  
Alexander Bardetsky ◽  
Helmi Attia ◽  
Mohamed Elbestawi
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
Cutting Tool ◽  
Minimum Quantity Lubrication ◽  
Metalworking Fluids ◽  
High Speed Machining ◽  
Cast Aluminum ◽  
Tool Wear Rate ◽  
Cast Aluminum Alloys ◽  
Lubricant Composition

The disadvantages of conventional metalworking fluids such as disposal problems, health problems and economic factors have led to the development of strategies to reduce their amount in metalworking. Recently, Minimum Quantity Lubrication (MQL) technology was developed and it seems to be a suitable alternative for economically and environmentally compatible production. It combines the functionality of lubrication with an extremely low consumption of lubricant and has a potential to replace metalworking fluids application in machining operations. The MQL lubricants are formulated with two major groups of additives; anti-wear (AW) additives and extreme pressure (EP) additives. When such lubricants are applied to the cutting zone, protective layers are formed on the interacting surfaces of the workpiece and the cutting tool. These layers prevent direct contact between the tool and chip surfaces, and, therefore reduce friction forces and tool wear. In order to utilize MQL to its full potential, it is essential to select appropriate lubricant composition for particular work material and machining parameters. The experimental study of different compositions of MQL lubricants is reported. The effectiveness of the lubricants are determined in terms of their ability to protect the cutting tool in high speed machining of cast aluminum alloys, which are widely used in automotive industry. The main objective of this research is to quantitatively evaluate the ability of lubricant’s additive composition to reduce the tool wear. This is reached through the comparison between the tool wear rate measured during the machining of aluminum cast alloy with the application of MQL, and the tool wear rate obtained in dry machining of the same alloy. Two kinds of the lubricants are evaluated; vegetable and synthetic. The content of AW and EP additives in each kind of lubricant was varied on three levels in order to capture the effect of the lubricant’s composition on tool wear. The result of the MQL lubricants evaluation is discussed and the recommendations for optimal lubricant composition are made.

A Strategy of Toolpath Generation for Finish Machining of Mold Cavity Based on Tool-Zmap Model

2009 ◽  
Vol 407-408 ◽  
pp. 273-278
Author(s):  
Yu Jun Cai ◽  
Chun Zheng Duan ◽  
Li Jie Sun
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
Cutting Tool ◽  
Geometric Model ◽  
Cutting Tools ◽  
Mold Cavity ◽  
High Speed Machining ◽  
Cutting Tool Wear ◽  
Finish Machining ◽  
Toolpath Generation

A strategy of toolpath generation based on Tool-Zmap geometric model has been proposed to achieve efficient finish machining of mold cavity. Considering cutting tool wear, the finish machining of mold cavity was performed using variable cutting tools of different diameter. Each cutting tool only cuts the corresponding area to avoid identifying machining characteristic and poor rigidity of cutting tool during high speed machining. Finally, the validity of presented strategy was experimentally affirmed by a machining example.

Effect of Different Coating Materials on Cutting Performance in High-Speed Machining of Mold Steels

2007 ◽  
Vol 364-366 ◽  
pp. 1026-1031
Author(s):  
Shen Yung Lin ◽  
S.H. Yu ◽  
M.L. Wu
Keyword(s):  
Surface Roughness ◽  
Surface Layer ◽  
Tool Wear ◽  
High Speed ◽  
Cutting Performance ◽  
Cutting Conditions ◽  
High Speed Machining ◽  
Coating Materials ◽  
High Speed Milling ◽  
Good Surface

Different materials coated on milling tools (tungsten carbide) such as TiCN, TiAlN, TiN and DLC are integrated in this study for the analysis of cutting performance such as tool wear, surface roughness and noise induced in high-speed machining of mold steels such as NAK80 and SKD61 under different combinations of cutting conditions. The study attempts to find out the advantages and adaptabilities in various coating materials being suitable for which cutting circumferences with specific performance request. High-speed milling experiments of NAK80 and SKD61 mold steels with four materials coating tools were carried out in the laboratory. The tool wear was measured through the toolmaker’s microscope and the roughness of the machined surface was measured by the roughness measuring instruments after each surface layer was removed from the workpiece in the experiment. Besides, the noise-mediator was used to detect cutting noise during each surface layer workpiece removing of high-speed milling process, and the curl chips removed from the workpiece were also collected for the result verifications. Good surface quality and small amount of tool wear can be achieved under the cutting conditions of high-speed revolutions, small feed rate and small depth of cut for four materials coating tools. From the observations of the annealing temperature from the removed chips and the analysis of the cutting noise levels, TiAlN material coating tool has the better tool life and it is suitable for rougher high-speed machining, while DLC material coating tool only has a good surface roughness in shallow cut and hence it is not suitable for high-speed machining of mold steel with excellent cutting performance request.

Effect of residual elements on the machinability of leaded free machining steels

1980 ◽  
Vol 295 (1413) ◽  
pp. 87-88 ◽  
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Tool Life ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Tool Material ◽  
High Speed Steel ◽  
Low Carbon ◽  
Wear Rates

The machinability of a material can be defined in terms of the wear rate of the cutting tool used to machine the material. The lower the tool wear rate or the greater the tool life the better the machinability. The wear processes of cutting tools are complicated, but recent work has shown that cutting tool wear rates during machining can be directly related to tool material wear rates when rubbing in a modified crossed cylinder wear experiment (Mills & Akhtar 1975). The wear of cutting tools can be simulated by simple experiments. Here I present results on the effect of total residual levels in leaded low carbon free machining steels on the tool life of M2 high speed steel. The results will be discussed in terms of a simple wear model.

Analyzing the Mechanisms of Cutting Tool Wear during the Machining of Corrosion-Resistant Steels

2019 ◽  
Vol 973 ◽  
pp. 120-124
Author(s):  
Pham H. Trung ◽  
Juliy L. Chigirinskiy
Keyword(s):  
Chemical Composition ◽  
Wear Rate ◽  
Tool Wear ◽  
Thermophysical Properties ◽  
Cutting Tool ◽  
Tool Material ◽  
Cutting Conditions ◽  
Hard Alloys ◽  
Carbide Tool ◽  
Corrosion Resistant

The study analyzes physicomechanical and thermophysical properties of hard alloys with due regard to their chemical composition; reveals the dependence of both the cutting properties and regularities of carbide tool wear from cutting conditions and thermophysical properties of tool material; describes a significant impact of not only mechanical but, first and foremost, thermophysical properties of instrumental and structural materials on tool wear; and identifies ways to reduce the wear rate of a cutting tool.

Tool wear in high speed machining

2000 ◽  
Vol 10 (PR9) ◽  
pp. Pr9-541-Pr9-546 ◽  
Author(s):  
A. Molinari ◽  
M. Nouari
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
High Speed Machining

A First Step towards a Tribological Approach to Investigate Cutting Tool Wear

2014 ◽  
Vol 611-612 ◽  
pp. 452-459 ◽  
Author(s):  
Giovenco Axel ◽  
Frédéric Valiorgue ◽  
Cédric Courbon ◽  
Joël Rech ◽  
Ugo Masciantonio
Keyword(s):  
Tool Wear ◽  
Cutting Tool ◽  
304L Stainless Steel ◽  
Fe Modelling ◽  
Wear Model ◽  
Cutting Tool Wear ◽  
The Will ◽  
Preliminary Study ◽  
The Impact ◽  
Macroscopic Parameters

The present work is motivated by the will to improve Finite Element (FE) Modelling of cutting tool wear. As a first step, the characterisation of wear mechanisms and identification of a wear model appear to be fundamental. The key idea of this work consists in using a dedicated tribometer, able to simulate relevant tribological conditions encountered in cutting (pressure, velocity). The tribometer can be used to estimate the evolution of wear versus time for various tribological conditions (pressure, velocity, temperature). Based on this design of experiments, it becomes possible to identify analytically a wear model. As a preliminary study this paper will be focused on the impact of sliding speed at the contact interface between 304L stainless steel and tungsten carbide (WC) coated with titanium nitride (TiN) pin. This experiment enables to observe a modification of wear phenomena between sliding speeds of 60 m/min and 180 m/min. Finally, the impact on macroscopic parameters has been observed.

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