DEVELOPMENT OF A COMPUTATIONAL MODEL TO INVESTIGATE THE THERMO-MECHANICAL BEHAVIOUR OF CUTTING TOOLS

Abstract

During machining, the cutting tool wears out and affects the machined surface quality and overall production cost. The prediction of tool wear and analysis of cutting mechanics has significant importance for process optimization and cutting-edge design. In this present study, an efficient FE simulation approach (Arbitrary Eulerian-Lagrangian) on the Abaqus/Explicit platform has been developed to improve the predictability of flank wear and to select the appropriate tool edge geometry in the orthogonal turning operation. The FE model was calibrated by comparing the simulation and experimental force values. A new approach was applied to capture the worn tool geometry based on the frictional stress value acting on the cutting tool. The effect of wear geometry on the cutting zone was investigated with respect to temperature, normal stress, sliding velocity, and plastic deformation. The experimental tool wear pattern and characteristics for the differently prepared edges were studied and compared to the thermo-mechanical value retrieved from the FE model. Tool wear for differently prepared edges was calculated using Usui’s wear rate equation, which was calibrated using a hybrid calibration method. The efficiency of the calibration method was investigated at different cutting speeds and feed rates. The performance of pre-coating edge preparation was evaluated in both experimental and numerical studies.