An FEM-based approach for tool wear estimation in machining

This study presents an FEM-based approach to predict the rate of flank wear evolution for uncoated cemented carbide tools in longitudinal turning processes. This novel approach combines the concept of experimental design and Response Surface Methodology (RSM) with Finite Element (FE) modelling of the cutting process, which allows for a fairly accurate tool wear prediction with a significantly lower computational cost compared to other available numerical methods. In the current approach, a series of three dimensional (3D) FE simulations were initially performed for different combinations of cutting data and tool flank geometries. The obtained results were used to establish the quadratic relation between the input variables and the responses required for tool wear prediction, such as interface temperature. Later, the flank wear rate equation was developed based on the relation between the volume loss due to wear and the dimensions of the worn tools. The results of the FE simulations were finally integrated with the established wear rate equation to estimate the flank wear evolution. The credibility of the presented approach was then assessed through estimation of the flank wear evolution rate for a wide range of cutting conditions. The predicted flank wear rates showed a good agreement with experimental measurements in most cases. The reasons for minor deviations from the experimental results were finally outlined. (C) 2016 Elsevier B.V. All rights reserved.