Physics-based approach for predicting dissolution‒diffusion tool wear in machining

Journal article, 2020

A new approach is proposed to predict the thermally-activated dissolution-diffusion wear of carbide tools. Departing from the iterative procedure used for such nonlinear processes, a direct response surface approach that correlates the cutting conditions and wear level to the interface temperature is presented. For prediction of wear evolution, a calibrated thermodynamic model that describes chemical interaction between the tool and workpiece materials is combined with the FE simulation of machining process, considering the pressure-dependent thermal constriction resistance phenomenon. The accuracy of predicting flank wear in turning C50 plain carbon steel ‒ where dissolution-diffusion wear mechanism prevails ‒ is validated experimentally.