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Estimation of Tool Wear in Orthogonal Cutting Using The Finite Element Analysis - 2004 - Journal of Materials Processing Technology PDF
Estimation of Tool Wear in Orthogonal Cutting Using The Finite Element Analysis - 2004 - Journal of Materials Processing Technology PDF
Engineering Research Center for Net Shape Manufacturing (ERC/NSM), The Ohio State University, Columbus, OH 43210, USA
b Institute of Machine Tools and Production Science, Universitt Karlsruhe (TH), Karlsruhe, Germany
Abstract
In metal cutting, tool wear on the toolchip and toolworkpiece interfaces (i.e. flank wear and crater wear) is strongly influenced by the
cutting temperature, contact stresses, and relative sliding velocity at the interface. These process variables depend on tool and workpiece
materials, tool geometry and coatings, cutting conditions, and use of coolant for the given application. Based on temperatures and stresses
on the tool face predicted by the finite element analysis (FEA) simulation, tool wear may be estimated with acceptable accuracy using an
empirical wear model.
The overall objective of this study is to develop a methodology to predict the tool wear evolution and tool life in orthogonal cutting
using FEM simulations. To approach this goal, the methodology proposed has three different parts. In the first part, a tool wear model for
the specified toolworkpiece pair is developed via a calibration set of tool wear cutting tests in conjunction with cutting simulations. In
the second part, modifications are made to the commercial FEM code used to allow tool wear calculation and tool geometry updating. The
last part includes the experimental validation of the developed methodology. The focus of this paper is on the modifications made to the
commercial FEM code in order to make reasonable tool wear estimates.
2003 Elsevier B.V. All rights reserved.
Keywords: Tool wear; Tool life; Orthogonal cutting; Finite element method (FEM); Wear mechanisms
1. Introduction
Tool wear has a large influence on the economics of the
machining operations. Thus, knowledge of tool wear mechanisms and capability of predicting tool life are important
and necessary in metal cutting. A view of the functional
elements that affect the wear of a cutting tool is illustrated
in Fig. 1 and can be summarized in four major groups,
as follows:
1. The workpiece material and its physical properties (mechanical and thermal properties, microstructure, hardness, etc.), which determine cutting forces and energy for
the applied cutting conditions.
2. The interface conditions: In 80% of the industrial cutting applications, coolants are used to decrease cutting
temperatures and likely reduce tool wear. Increasingly
new technologies, such as the minimum liquid lubrication, have been developed to reduce the cost of coolant
that makes up to 16% of the total machining costs [1].
Corresponding author.
E-mail address: altan.1@osu.edu (T. Altan).
0924-0136/$ see front matter 2003 Elsevier B.V. All rights reserved.
doi:10.1016/S0924-0136(03)00847-1
Y.-C. Yen et al. / Journal of Materials Processing Technology 146 (2004) 8291
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Fig. 3. Summary of selected empirical tool life models and tool wear rate
models [711,13].
tool wear rate models require the knowledge of wear mechanisms associated with the tool and workpiece materials and
the range of cutting conditions used. It is generally accepted
that for carbide tools under practical cutting conditions, the
wear rate is dominated by a temperature-sensitive diffusion process, in particular at higher cutting speeds [1012].
Takeyama and Murata derived a fundamental wear rate equation by considering abrasive wear, which is proportional to
cutting distance, and diffusive wear [13]. Mathew [10] analyzed the tool wear of carbide tools when machining carbon steels and results have shown that the Takeyama and
Muratas diffusion equation can be used to effectively relate the tool wear rate to the average contact temperature
of the tool. At cutting temperature higher than 800 C, the
first abrasive term G(V, f), Fig. 3, can be neglected [10].
Molinari and Nouari [11] recently proposed a new diffusion
wear model by considering the contact temperature to be
the main parameter controlling the rate of diffusion in the
normal direction to the toolchip interface.
Usui et al. in the tool wear study for carbide tools
[12,14,15] derived a wear rate model based on the equation of adhesive wear, which involves temperature, normal
stress, and sliding velocity at the contact surface. Their results in machining different carbon steels (0.150.46% C)
showed that both flank wear and crater wear obey the same
wear mechanism and can be described by the proposed
wear model. A change of slope of the wear characteristic
line at near 877 C (1150 K) was observed, and according
to the authors, attributed to the formation of fragile carbide
compounds and disappearance of WC grains (a diffused
layer) in the tool material at high temperatures. It should
be noted that despite considering different tool wear mechanisms, Mathew [10] and Usui and coworkers [14] both
could fit the experimental wear data well due to the fact that
the diffusive and adhesive wear models used, respectively,
4. Research objectives
The overall objective of this study is to develop a
FEM-based methodology to predict the evolution of tool
wear and tool life for orthogonal cutting. Specifically, the
research tasks include:
(i) implementation of tool wear rate model(s) in the commercial FEM code (DEFORM -2D) that relates the
wear rate to the predicted process variables;
Y.-C. Yen et al. / Journal of Materials Processing Technology 146 (2004) 8291
Fig. 4. Simulation procedure for tool wear prediction using DEFORM 2D.
85
Fig. 5. Cutting simulation for a worn tool (VB = 0.1 mm) using the
Konti-Cut module.
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Fig. 6. Variation of calculated workpiece and tool temperatures at the tracking points near the contact interface.
respectively. The Eulerian point tracking of the chip was implemented in the FEM code with user-defined FORTRAN
subroutines.
In the case of Fig. 5, the contact temperatures on both
sides of the toolchip and toolworkpiece interfaces were
plotted by defining two tracking points on the rake face (TP1
and TP2) and one tracking point on the flank face (TP3), as
shown in Fig. 6. The three curves with solid symbols represent the tool face temperatures obtained from the Lagrangian
point tracking, whereas the other three curves represent the
inner surface temperatures of the chip obtained from the Eulerian point tracking. After approximately 0.6 ms, all curves
appear to have reached a nearly constant value.
In the case of Fig. 6, a large interface heat transfer coefficient, hint , was defined for the contact interface during
simulation, assuming a perfect interface heat transfer condition. It can be noted from the figure that the surface temperatures of the tool tend to be higher than that of the workpiece and chip counterparts near the same locations of the
interface. This may be explained by the fact that the friction heat transferred to the chip is immediately transported
away by the chip flow, whereas the friction heat conducted
to the tool gets accumulated near the tool surface and takes
time to diffuse into the inner region of the tool. Experimental results of temperatures using the two-color pyrometry
measurement during cutting have shown similar observations [24]. In addition, the flank face temperatures are lower
than the rake face temperatures, consistent with the results
given in [14], due to less plastic deformation in the tertiary
shear zone.
The Konti-Cut simulation has two other features:
1. It avoids possible convergence and contact problems
when the long chip produced curls down and touches
the uncut workpiece surface. However, it should also
be pointed out that the use of Konti-Cut has a potential risk of underestimating the chip contact length and
Y.-C. Yen et al. / Journal of Materials Processing Technology 146 (2004) 8291
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Along with the wear rate data, the new rake face and flank
face geometries of the tool due to tool wear were calculated
and used in Phase 4 to generate the new input keyword file
for the next simulation. Considering the nature of the flat
flank wear land observed in the cutting tool, two methods
were adopted for the modification of the flank face geometry: (1) updating by individual nodal movements and (2)
updating based on the averaged values of cutting variables
for the flank wear land. This is because any sharp peaks on
the flank wear surface are virtually unstable and will be torn
flat immediately by continuous machined workpiece deformation. For the modification of the rake face geometry, only
the individual nodal movement method was used. Another
possible method for updating the tool geometry might be
through deletion of the tool surface elements.
5.4.1. Updating by individual nodal movements
The evolution of tool wear on the rake face and tool tip (referred to as tool rake hereafter) normally follows a concave
shape (crater wear) in the cross-sectional profile. Therefore,
tool rake adjustments by moving individual surface nodes in
the normal direction can be used to account for varying wear
depths along the tool rake face. The wear depth for each
Fig. 8. Results of the pure thermal analysis for the tool with the calculated heat flux conditions based on Fig. 7.
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Y.-C. Yen et al. / Journal of Materials Processing Technology 146 (2004) 8291
where (xX , yX )|t=tk and (xX , yX )|t=tk+1 are the Cartesian coordinates of the node X before and after the nodal movement, respectively.
Fig. 9. Schematic illustration of updating the tool geometry by the individual nodal movement method.
i = 1, . . . , N
(2)
where w
i,k = dWi /dtk is the wear rate for the node i at time
tk and is assumed to be constant throughout the time period
tk . N is the total number of the contact nodes. di,k the
nodal displacement for the node i corresponding to tk . The
total wear depth for the node i (di ) is thus equal to the vector
sum of all incremental nodal displacements associated with
the node i throughout the total cutting time:
d i = d i,0 + d i,1 + + d i,k +
(3)
(5)
dl
dl
w
dt
=
tan
tan
tan
(6)
VB =
dt
t
(7)
tan
tan
t
In Phase 3 of the simulation, the average wear rate for the
existing flank wear was first calculated. For the user-defined
t, a new flank wear width (= VB + VB) was obtained
using Eq. (7). Then, the updating of the new flank wear geometry was achieved by offsetting the entire flank wear line
along the inward-normal direction by the distance of wt.
Y.-C. Yen et al. / Journal of Materials Processing Technology 146 (2004) 8291
89
Thus, the tool wear models that account for gradual wear
formation like Eq. (1) may not be suitable for the case of
a sharp edge. It is also important to note that as the Usuis
wear model for carbon steels considers adhesive wear,
it may better describe the flank wear behavior at higher
temperatures after a small flank wear land has formed.
6.2. Simulation of a worn tool with a pre-defined flank
wear width
Fig. 10. Result of wear rate (left) and updated rake face geometry (right)
for an uncoated sharp tool (vc = 300 m/min, f = 0.145 mm/rev).
Fig. 11. Predicted results of the wear rate distribution (before modifying tool geometry) and the updated geometries of crater wear and flank wear for
the tool with an initial flank wear land of 0.06 mm (AISI-1045 workpiece vs. uncoated carbide, vc = 300 m/min, f = 0.145 mm/rev, : location of the
maximum wear rate).
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Y.-C. Yen et al. / Journal of Materials Processing Technology 146 (2004) 8291
back face of the tool, and (e) other boundary heat flux
components ignored in Fig. 7.
(ii) The values of the wear constants A and B when Usuis
wear rate model was used.
(iii) Numerical errors associated with the frequent remeshing and data interpolation from the old mesh to the new
mesh throughout the simulation.
its final shape. For all the cases, the flank wear geometry
was modified using the second updating method (average
values of process variables).
It is seen from the figure that the wear rates of crater wear
and flank wear are of the same order (104 ) and hence the
increase of both types of tool wear is quite consistent. The
location of the maximum wear rate is on the tool rake face
and is nearly coincident with that of the maximum cutting
temperature. In addition, a region of very low wear rates is
observed close to the tool radius on the rake face side. This
region corresponds well to the experimental result of the
worn tool geometry, which usually features a small flat face
near the cutting edge that is almost unaffected by cutting
(denoted by KF in the ISO-3685 standard [26]).
Similarly, Fig. 12 shows the results for another test simulation, where both crater wear and flank wear land (VB =
0.1 mm) were initially included in the tool geometry. It can
be seen from Fig. 12(a) that large wear rates are concentrated on the upper region of the crater wear and thus cause
the crater wear to develop in width. This is caused by the
localized high temperatures and normal stresses due to the
restricted chip flow. On the other hand, moderate values of
wear rate are observed at the middle toolchip contact region and cause the crater wear to develop in depth. Fig. 12(b)
shows that the chip flow is completely conformed to the updated crater wear profile, leading to a reduced chip-curling
radius.
The experimental results from the cutting tests under the
same cutting conditions [27] have shown that the tool life
of a carbide tool (Kennametal grade K68) is around 1 min
based on a criterion of VB = 0.2 mm. This implies that
the wear rate values obtained in the simulations may be
underestimated, hence requiring a large t. This inaccuracy
may be due to the following error sources:
(i) The solution of the steady state temperature of the tool,
which involves a few uncertainties: (a) the interface
heat transfer coefficient, hint , (b) the friction model (a
constant shear factor m = 0.6 was used), (c) calculation of heat partition for the friction heat generated at
the interface, (d) effect of tool size and thermal boundary conditions (T = 20 C), defined on the top and
Acknowledgements
This study was partially supported by the National Science Foundation through the ongoing NSF project (Grant
no. DMI-9821020). The authors would like to thank Dr.
P. Chigurupati and Dr. W.-T. Wu at Scientific Forming
Technologies Inc. (DEFORM) and Dr. H.-W. Raedt at
Y.-C. Yen et al. / Journal of Materials Processing Technology 146 (2004) 8291
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