Effect of Tool Flank Wear on the Orthogonal Cutting Process

2007 ◽  
pp. 705-710 ◽  
Author(s):  
X.L. Zhao ◽  
Yong Tang ◽  
Wen Jun Deng ◽  
F.Y. Zhang
Keyword(s):  
Flank Wear ◽  
Orthogonal Cutting ◽  
Cutting Process ◽  
Tool Flank Wear

Effect of Tool Flank Wear on the Orthogonal Cutting Process

2007 ◽  
Vol 329 ◽  
pp. 705-710 ◽  
Author(s):  
X.L. Zhao ◽  
Yong Tang ◽  
Wen Jun Deng ◽  
F.Y. Zhang
Keyword(s):  
Cutting Forces ◽  
Cutting Tool ◽  
Flank Wear ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Element Model ◽  
Cutting Process ◽  
Temperature Fields ◽  
Tool Flank Wear ◽  
Chip Separation

A coupled thermoelastic-plastic plane-strain finite element model is developed to study orthogonal cutting process with and without flank wear. The cutting process is simulated from the initial to the steady-state of cutting force and cutting temperature, by incrementally advancing the cutting tool forward. Automatic continuous remeshing is employed to achieve chip separation at the tool tip regime. The effect of the degree of the flank wear on the cutting forces and temperature fields is analyzed. With the flank wear increasing, the maximum cutting temperature values on the workpiece and cutting tool increase rapidly and the distribution of temperature changes greatly. The increase of tool flank wear produced slight increase in cutting forces but significant increase in thrust forces.

Predictive Analytical and Thermal Modeling of Orthogonal Cutting Process—Part II: Effect of Tool Flank Wear on Tool Forces, Stresses, and Temperature Distributions

2005 ◽  
Vol 128 (2) ◽  
pp. 445-453 ◽  
Author(s):  
Yiğit Karpat ◽  
Tuğrul Özel
Keyword(s):  
Flank Wear ◽  
Thermal Modeling ◽  
Orthogonal Cutting ◽  
Force Model ◽  
Stress Distributions ◽  
Tool Flank Wear ◽  
Temperature Distributions ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

In this paper, predictive modeling of cutting and ploughing forces, stress distributions on tool faces, and temperature distributions in the presence of tool flank wear are presented. The analytical and thermal modeling of orthogonal cutting that is introduced in Part I of the paper is extended for worn tool case in order to study the effect of flank wear on the predictions. Work material constitutive model based formulations of tool forces and stress distributions at tool rake and worn flank faces are utilized in calculating nonuniform heat intensities and heat partition ratios induced by shearing, tool-chip interface friction, and tool flank face-workpiece interface contacts. In order to model forces and stress distributions under the flank wear zone, a force model from Waldorf (1996) (“Shearing Ploughing, and Wear in Orthogonal Machining,” Ph.D. thesis, University of Illinois at Urbana-Champaign, IL) is adapted. Model is tested and validated for temperature and force predictions in machining of AISI 1045 steel and AL 6061-T6 aluminum.

3328 In-process Tool Flank Wear Detection in Intermittent Cutting Process by Face Milling

2011 ◽  
Vol 2011.6 (0) ◽  
pp. _3328-1_-_3328-6_
Author(s):  
Mitsuaki MURATA ◽  
Syuhei KUROKAWA ◽  
Osamu OHNISHI ◽  
Michio UNEDA ◽  
Toshiro DOI
Keyword(s):  
Flank Wear ◽  
Face Milling ◽  
Cutting Process ◽  
Tool Flank Wear ◽  
Intermittent Cutting
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