2D FEM Estimate of Tool Wear in Hard Cutting Operation: Extractive of Interrelated Parameters and Tool Wear Simulation Result

Tool wear plays an important part during cutting process, and wear loss has a close relationship with cutting condition, which affects machined surface mostly. In order to accomplish tool wear prediction in way of FEM, based on founding of cutting model under steady state, interrelated parameters needed for tool wear prediction, such as cutting temperature, contact pressure and raletive sliding velocity are extracted. By compiling Python subprogram and using Abaqus tool in hard cutting process PCBN tool wear is predicted, which provide foundation for optimizing cutting condition.

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2D FEM Estimate of Tool Wear in Hard Cutting Operation: Tool Wear and Simulation of Hard Cutting Process under Steady State

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.69-70.306 ◽

2009 ◽

Vol 69-70 ◽

pp. 306-310

Author(s):

Fu Gang Yan ◽

Cai Xu Yue ◽

Xian Li Liu ◽

Yu Fu Li ◽

Shu Yi Ji

Keyword(s):

Steady State ◽

Tool Wear ◽

Model Simulation ◽

Cutting Temperature ◽

Cutting Process ◽

Workpiece Material ◽

Machined Surface ◽

Fem Model ◽

Fem Method ◽

Hard Cutting

Tool wear plays an important role in cutting process research. It affects the quality of machined surface and cutting parameter to a great extent, such as cutting force, cutting temperature and cutting quiver. In order to predict tool wear in hard cutting process by using FEM method, the character of tool wear during cutting process is presented firstly, and Usui’s tool wear rate model is introduced. Then the FEM model for steady state cutting process using Abaqus is established. FEM model describes the workpiece material characteristic accurately for the process of PCBN tool cutting GCr15 by adoptiving Johnson-Cook constitutive model. Simulation results of steady cutting process offer foundation to simulate tool wear.

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Finite Element Method Based Modeling for Tool Wear Prediction in Orthogonal Cutting Process

Journal of Engineering Science and Military Technologies ◽

10.21608/ejmtc.2017.21079 ◽

2017 ◽

Vol 17 (17th International Conference) ◽

pp. 1-14

Author(s):

A Ali ◽

B El Hossainy ◽

C Abd-Rabou

Keyword(s):

Finite Element Method ◽

Finite Element ◽

Tool Wear ◽

Orthogonal Cutting ◽

Cutting Process ◽

Wear Prediction ◽

Tool Wear Prediction ◽

Element Method

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3D Finite Element Simulation of Hard Turning

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.69-70.11 ◽

2009 ◽

Vol 69-70 ◽

pp. 11-15 ◽

Cited By ~ 2

Author(s):

Cai Xu Yue ◽

Xian Li Liu ◽

Dong Kai Jia ◽

Shu Yi Ji ◽

Yuan Sheng Zhai

Keyword(s):

Shear Failure ◽

Cutting Temperature ◽

Failure Criteria ◽

Cutting Process ◽

Cutting Condition ◽

Residual Stress Field ◽

Surface Residual Stress ◽

Element Simulation ◽

Side Flow ◽

Hard Cutting

A 3D model is established in this paper to simulate cutting process of PCBN tool cylindrical cutting hardened steel GCr15 using ABAQUS/Explicit. The model effectively overcomes serious element distortions and cell singularity in high strain domain caused by material large deformation by adopting shear failure criteria and element deletion criteria. In this study cutting force, cutting temperature, surface residual stress field as well as side flow are forecasted of hard cutting process with chamfering tool preparation. It shows that satisfactory results could be obtained by FEM. The simulation results provide theoretical basis for studying hard cutting mechanism and selecting the best cutting condition in practical.

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Mesh node rigid moving algorithm for the uncoated milling cutter tool wear prediction considering periodic process variables

Proceedings of the Institution of Mechanical Engineers Part C Journal of Mechanical Engineering Science ◽

10.1177/0954406216646602 ◽

2016 ◽

Vol 231 (19) ◽

pp. 3635-3648 ◽

Cited By ~ 1

Author(s):

H-B Liu ◽

Y-Q Wang ◽

D Wu ◽

B Hou

Keyword(s):

Tool Wear ◽

Fem Simulation ◽

High Speed Steel ◽

Periodic Process ◽

Process Variables ◽

Wear Prediction ◽

Milling Cutter ◽

Tool Wear Prediction ◽

Cutting Model ◽

Mesh Node

Milling is a typical intermittent cutting process. As a result, tool wear is generated cyclically due to periodic process variables. However, the traditional tool wear prediction strategy based on continuous cutting model is no longer applicable. In this paper, a novel geometric approach through mesh node rigid moving for the milling cutter tool wear prediction has been developed. Firstly, a unified tool wear predictive model is established through bridging the two wear configurations before and after worn. A coupled abrasive–diffusive model is employed to calculate the tool wear volume of each point on tool face. Further, a novel iterative algorithm for tool wear prediction through mesh node rigid moving layer-by-layer and process variables redistribution is designed in discrete-time domain, which is generally decomposed into two phases according to cutting heat equilibrium state, FEM simulation and offline calculation. Last, a series of numerical and saw-milling experiments for flank wear prediction were implemented to verify the developed approach. The AISI304 and the high vanadium high-speed steel tool without coating were adopted. By comparison, the predicted results were consistent with the experimental overall. It has been proved that the proposed approach is more effective than pure FEM simulation and is suitable for long-term milling tool wear prediction.

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Finite Element Method Based Modeling for Tool Wear Prediction in Orthogonal Cutting Process

International Conference on Aerospace Sciences and Aviation Technology ◽

10.21608/asat.2017.22380 ◽

2017 ◽

Vol 17 (AEROSPACE SCIENCES) ◽

pp. 1-14

Author(s):

A. Ali ◽

B. El Hossainy ◽

C. Abd-Rabou

Keyword(s):

Finite Element Method ◽

Finite Element ◽

Tool Wear ◽

Orthogonal Cutting ◽

Cutting Process ◽

Wear Prediction ◽

Tool Wear Prediction ◽

Element Method

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The Simulation Analysis of Friction Effect on Cutting Process

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.314-316.1065 ◽

2011 ◽

Vol 314-316 ◽

pp. 1065-1068

Author(s):

Shu Jun Li ◽

Xiao Hang Wan ◽

Zhao Wei Dong ◽

Yuan Yuan

Keyword(s):

Friction Coefficient ◽

Coulomb Friction ◽

Simulation Analysis ◽

Orthogonal Cutting ◽

Cutting Temperature ◽

Fem Analysis ◽

Cutting Process ◽

Machined Surface ◽

System Description ◽

Cutting Model

Adopted the Lagrange quality point coordinate system description method used the FEM analysis software, the reasonable two-dimension heat-mechanic coupling orthogonal cutting model is established in this paper, which uses the ameliorated Coulomb friction theory to simulate the friction status between the chips and tools. This paper simulates the cutting process with different friction coefficient. It can draw conclusions that the cutting forces and the residual stresses of machined surface are increasing with the raising of touching length of rake face and chip, the raising of cutting temperature. The friction coefficient has the important effect on the machining quality.

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Gear Hobbing Cutting Process Simulation and Tool Wear Prediction Models

Journal of Manufacturing Science and Engineering ◽

10.1115/1.1430236 ◽

2001 ◽

Vol 124 (1) ◽

pp. 42-51 ◽

Cited By ~ 34

Author(s):

K.-D. Bouzakis ◽

S. Kombogiannis ◽

A. Antoniadis ◽

N. Vidakis

Keyword(s):

Tool Wear ◽

High Speed ◽

Prediction Models ◽

Numerical Models ◽

High Speed Steel ◽

Cutting Process ◽

Wear Prediction ◽

Tool Wear Prediction ◽

Gear Hobbing ◽

The Individual

Gear hobbing is an efficient method to manufacture high quality and performance toothed wheels, although it is associated with complicated process kinematics, chip formation and tool wear mechanisms. The variant cutting contribution of each hob tooth to the gear gaps formation might lead to an uneven wear distribution on the successive cutting teeth and to an overall poor tool utilization. To study quantitatively the tool wear progress in gear hobbing, experimental-analytical methods have been established. Gear hobbing experiments and sophisticated numerical models are used to simulate the cutting process and to correlate the undeformed chip geometry and other process parameters to the expected tool wear. Herewith the wear development on the individual hob teeth can be predicted and the cutting process optimized, among others, through appropriate tool tangential shifts, in order to obtain a uniform wear distribution on the hob teeth. To determine the constants of the equations used in the tool wear calculations, fly hobbing experiments were conducted. Hereby, it was necessary to modify the fly hobbing kinematics, applying instead of a continuous tangential feed, a continuous axial one. The experimental data with uncoated and coated high speed steel (HSS) tools were evaluated, and correlated to analytical ones, elaborated with the aid of the numerical simulation of gear hobbing. By means of the procedures described in this paper, tool wear prediction as well as the optimization of various magnitudes, as the hob tangential shift parameters can be carried out.

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