A framework for the physics-based estimation of tool wear in machining process (WEAR-FRAME)

Research Project, 2021 – 2024

Purpose and goal:
WEAR-FRAME aims to develop a generic physics-based platform (software) for modelling and simulation of tool wear in machining of case-hardening and low alloyed steels. This platform benefits from semi-analytical and Finite Element based methods for the estimation of thermo-mechanical loads on the tool as well as throughput DFT-MD and CALPHAD simulations to obtain the material inputs for tool wear estimation. The goal of this simulation-based platform is to enable the optimization and adaptation of machining processes to batch-to-batch material variations.

Expected results and effects:
The WEAR-FRAME objectives target the optimization and adaptation of machining processes to material variations: 1) Availability - 10% lower lead time when introducing material in production line due to better control of material variations 2) Quality - improvement in machined and ground surface quality due to better control (15%) of tool-change & dressing intervals. 3) Performance increase (10-15%) resulting from simulation-based predictions of the tool wear; and use of optimal machining parameters (i.e. machining data); improved energy consumption and resource efficiency.

Planned approach and implementation:
WEAR-FRAME consortium includes three OEMs: Scania, Volvo AB and Seco Tools, one SME: Gnosjö Automatsvarvning, one association: Skärteknikcentrum Sverige (SKTC) and two departments at Chalmers University of Technology. The project comprise of 6 work-packages: WP1: Industrial data collection and analytics, WP2: Experimental machining tests, WP3: Material Characterisation, WP4: Modelling & simulation - software integration, WP5: Demonstration, WP6: project management & dissemination. The industrial and research partners collaborate closely to achieve the project goals.