Estimation of Two-Dimension Tool WearBased on Finite Element Method

Sections

Chapter 1 Introduction
1.1 State Of Art: Finite Element Simulation Of Cutting Process
1.1.1 Numerical Aspects
1.1.1.1 Approach
1.1.1.2 Mesh Adaptivity
1.1.2 Mechanical Aspects
1.1.2.1 Contact And Friction
1.1.2.2 Material Constitutive Model
1.1.2.3 Chip Separation
1.2 Technical Background About Tool Wear
1.2.1 Wear Types In Metal Cutting
1.2.2 Wear Mechanism
1.2.3 Tool Wear Model
1.3 Research Of Tool Wear With Finite Element Methods
1.3.1 Comparison Between FEM Method And Empirical Method
1.3.2 State Of Art: Numerical Implementation Of Tool Wear Estimation
1.3.2.2 Tool Wear Estimation With FEM
1.3.2.3 Summary Of Literature
Chapter 2 Objective And Approach
2.1 Objectives
2.2 Approach
Chapter 3 Chip Formation Simulation Technology
3.1 Introduction
3.1.1 Explicit Algorithm In Chip Formation Simulation
3.1.1.1 Dynamic Analysis Procedure
3.1.1.2 Thermal Analysis Procedure
3.1.2 Stability Limit
3.2 Continuous Chip Formation Simulation
3.2.1 Limitation Of The Existing Chip Formation Models
3.2.2 Advantages Of The New-developed Chip Formation Model
3.2.3.1 Boundary Region Types
3.2.3.2 Geometry Features
3.2.3.3 Curvature Refinement
3.2.4 Analysis Steps
3.2.4.1 Initial Chip Formation
3.2.4.3 Continuous Steady-state Chip Formation
3.2.5 Results & Discussion
3.2.5.1 Stress Analysis
3.2.5.2 Plastic Strain Analysis
3.2.5.3 Strain Rate
3.2.5.4 Temperature Analysis
3.2.5.5 Verification With Experimental Data
3.3 Chip Formation Simulation For Milling Operation
3.3.1 Chip Separation
3.3.1.1 Shear Failure Criterion
3.3.1.2 A Numerical Method To Determine Strain At Failure
3.3.2 Chip Formation Modeling
3.3.3 Result & Discussion
3.3.3.1 Stress Analysis
3.3.3.2 Cutting Temperature
3.3.3.3 Cutting Force Analysis
3.4 Summaries & Conclusion
Chapter 4 Heat Transfer Analysis In Metal Cutting
4.1 Introduction
4.2 General Considerations
4.2.1 Geometry And Mesh
4.2.2 Heat Flux
4.3 In Turning Operation
4.3.1 Modeling
4.3.2 Results & Discussion
4.4 In Milling Operation
4.4.1 On Workpiece
4.4.1.1 Modelling
4.4.1.2 Results & Discussion
4.4.2 On Tool
4.4.2.1 Modeling
4.4.2.2 Results & Discussion
4.4.2.3 Application Of Preheated Cutting Tool
4.5 Summaries & Conclusion
Chapter 5 Estimation Of Tool Wear In Turning Operation
5.1 Introduction
5.2 Tool Wear Calculation Program Design
5.3 Modeling Procedure
5.3.1 Chip Formation And Heat Transfer Analysis
5.3.1.1 Normal Pressure
5.3.1.2 Sliding Velocity
5.3.1.3 Tool Temperature
5.3.2 Wear Rate Calculation
5.3.3 Nodal Move Direction
5.3.3.1 Dividing Node
5.3.3.2 On Rake Face
5.3.3.3 On Flank Face
5.3.4 Cutting Time Increment Calculation
5.3.4.1 Flank Wear Calculation Subroutine
5.3.4.2 Cutting Time Increment Searching Procedure
5.3.5 Nodal Displacement
5.3.6 Tool Geometry Updating
5.3.6.1 Step 1: Initial Tool Wear Profile
5.3.6.2 Step 2: Adjustment
5.4 Results & Discussion
5.4.1 Tool Wear
5.5 Summaries & Conclusion
Chapter 6 Estimation Of Tool Wear In Milling Operation
6.1 Introduction
6.2 Tool Wear Calculation Program Design
6.3 Modeling Procedure
6.3.1 Chip Formation Analysis
6.3.2 Heat Transfer Analysis
6.3.3 Nodal Average Wear Rate Calculation
6.3.3.1 Discussion About The Calculation Method Of Nodal Average Wear Rate
6.3.3.2 Classification Of Workpiece Node
6.3.4 Nodal Move Direction
6.3.4.1 Dividing Node
6.3.4.2 On Rake Face
6.3.4.3 On Flank Face
6.3.5 Cutting Time Increment Calculation
6.3.5.1 Flank Wear Calculation Subroutine
6.3.5.2 Cutting Time Increment Searching Procedure
6.3.6 Tool Geometry Updating
6.4 Results & Discussion
6.5 Summaries & Conclusion
Chapter 7 Summary And Prospect
7.1 Summaries
7.2 Prospect
References

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