An FEM-based approach for tool wear estimation in machining
An FEM-based approach for tool wear estimation in machining
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DOI：
10.1016/j.wear.2016.08.007
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发表时间：
2016-12-15
期刊：
影响因子：
5
通讯作者：
Nyborg, Lars
中科院分区：
文献类型：
--
作者：
Malakizadi, Amir;Gruber, Hans;Nyborg, Lars
本研究提出了一种基于有限元的方法来预测纵向车削过程中未涂层硬质合金刀具的侧面磨损演变速率。这种新颖的方法将实验设计和响应面方法（RSM）的概念与切削过程的有限元（FE）建模相结合，与其他可用的数值方法相比，可以相当准确地预测刀具磨损，且计算成本显著降低。在目前的方法中，首先对切削数据和刀具侧面几何形状的不同组合进行了一系列三维（3D）有限元模拟。利用所得结果建立了输入变量与刀具磨损预测所需响应（如界面温度）之间的二次关系。然后，根据磨损体积损失与磨损刀具尺寸的关系，建立了齿面磨损率方程。最后，将有限元模拟结果与建立的磨损率方程相结合，对齿面磨损演化进行估计。然后通过估计广泛切削条件下的侧面磨损演化率来评估所提出方法的可信度。在大多数情况下，预测的侧翼磨损率与实验测量结果吻合良好。最后概述了与实验结果偏差较小的原因。(C) 2016 Elsevier B.V.版权所有
This study presents an FEM-based approach to predict the rate of flank wear evolution for uncoated cemented carbide tools in longitudinal turning processes. This novel approach combines the concept of experimental design and Response Surface Methodology (RSM) with Finite Element (FE) modelling of the cutting process, which allows for a fairly accurate tool wear prediction with a significantly lower computational cost compared to other available numerical methods.In the current approach, a series of three dimensional (3D) FE simulations were initially performed for different combinations of cutting data and tool flank geometries. The obtained results were used to establish the quadratic relation between the input variables and the responses required for tool wear prediction, such as interface temperature. Later, the flank wear rate equation was developed based on the relation between the volume loss due to wear and the dimensions of the worn tools. The results of the FE simulations were finally integrated with the established wear rate equation to estimate the flank wear evolution. The credibility of the presented approach was then assessed through estimation of the flank wear evolution rate for a wide range of cutting conditions. The predicted flank wear rates showed a good agreement with experimental measurements in most cases. The reasons for minor deviations from the experimental results were finally outlined. (C) 2016 Elsevier B.V. All rights reserved.