Modelling of metal cutting tool wear based on Archard’s wear equation

Summary, in English

This article deals with an essential problem in the metal cutting industry, the problem of predicting tool wear and tool life. This is also a problem that has been studied by academia for the last century, often with very little added knowledge. The possibility to replace a large number of systematic wear tests with only a few specially designed tests provides new potentials for rapid information collection and technology shifts. In the article a physically based model describing the tool flank wear during metal cutting is presented. The basis of the model work is a modified version of Archard’s wear equation. The results from the wear model are compared to Taylor’s well known tool wear diagrams. The two models are well correlated within the essential parameter range. The developed model requires a minimum of wear tests to provide the necessary basis for calculations. Only two experiments constitute the fixed point in the model. Other process conditions, that the actually tested, with other mechanical and thermal load, are interpolated or extrapolated around the experimentally fixed points. The mechanical and thermal loads are calculated and are a vital part of the model. The model generates tool wear diagrams and tool life predictions as function of cutting speed vc and theoretical chip thickness h1. A major part of this work has been performed in the SSF project Shortcut.