Predictive modeling for flank wear progression of coated carbide tool in turning hardened steel under practical machining conditions

Growing needs for economical and environmental friendly manufacturing processes have increased usage of coated carbide tools in dry and high-speed machining of hardened steel. However, most undesirable characteristic of the machining process is tool wear; especially the flank wear, which adversely affects the dimensional accuracy and product quality. Therefore, prediction of flank wear progression will be extremely valuable. In the present study, a flank wear rate model is developed incorporating abrasion, adhesion, and diffusion as dominant wear mechanisms. Given the cutting conditions, tool geometry, and workpiece and cutting tool material properties, the model predicts flank wear progression with machining time. Developed model is calibrated and experimentally validated in turning of hardened AISI 4340 steel at different levels of hardness using chemical vapor deposition (CVD)-applied multilayer TiCN/Al2O3/TiN-coated carbide tool under practical 3-D machining conditions. As predicted results generally agree well with the experimental observations, proposed model could be helpful to predict the flank wear progression and hence to support the optimization studies within the domain of the cutting parameters.