A thorough understanding of the material removal process in cutting is essential in selecting the tool material and in design, and also in assuring consistent dimensional accuracy and surface integrity of the finished product. Tool wear in cutting process is produced by the contact and relative sliding between the cutting tool and the workpiece, and between the cutting tool and the chip under the extreme conditions of cutting area. This paper presents the information on development of study on theoretical analysis and numerical simulation of tool wear in all over the world. Hidden Markov models (HMMs) were introduced to estimate tool wear in cutting, which are strongly influenced by the cutting temperature, contact stresses, and relative strains at the interface. Finite element method (FEM) is a powerful tool to predict cutting process variables, which are difficult to obtain with experimental methods. The objective of this work focuses on the new development in predicting the tool wear evolution and tool life in orthogonal cutting with FEM simulations.

A review of tool wear estimation using theoretical analysis and numerical simulation technologies

Theoretical predictions and experimental validations on machining the Nimonic C-263 super alloy

Prediction of cutting forces and instantaneous tool deflection in micro end milling by considering tool run-out

Milling operations are very common in manufacturing. Often it represents the last operation, determining the final product quality. Then an accurate mathematical model is important in order to design the cutting process, in terms of cutting process, and the geometry of the insert, for tool manufacturers. The finite element modeling (FEM) simulation permits the prediction of the cutting forces, stresses, and temperatures of the cutting process. The 2D FEM can be a reasonable approximation, where the deformation can be considered plain. For the milling operations, this assumption can be suitable if the depth of cut is much bigger than nose radius. But in the normal situation the insert has a complex geometry and the bidimensional model of the milling operation is not appropriate. The 3D FEM involves different element formulations, different remeshing algorithm, and different boundary conditions, so an independent approach is necessary. The approach followed in this paper is to model three-dimensionally the milling operation, considering the real geometry of the insert. The FEM simulation is carried out with a commercial code (3D DEFORM™). First the rheological model has been calibrated using OXCUT software, developed at the ERC/NSM, and a sensitivity analysis about friction model has been performed. Milling tests are conducted and the measured cutting forces are compared to finite element modeling results. The results show an acceptable agreement with experimental results in the range of cutting speed and feed rate considered.

E. Ghassemieh

Papers

Simulation of three-dimension cutting force and tool deflection in the end milling operation based on finite element method