Application of tool wear simulation in cutting tool development

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Within the prior project 'Simulation of tool wear for the machining with geometrically defined cutting edge' a simulation tool for the prediction of tool wear of uncoated cBN inserts in hard turning has been developed. The knowledge and methods of the special case shall be transferred to a broader range of industrial applications in the following, which will be arranged by a close cooperation with the application partners Kennametal and Kistler Automotive.For a useful practical application, the methodology of the tool wear simulation has to be enhanced. Due to the importance of coated tools, a main objective of the proposal is to extend the simulation capabilities to the simulation of the combined wear of the tool's coating and substrate. Within this aspect, further development, calibration procedures and software implementations are necessary. In addition, the simulation methodology shall be tested and validated for a broader spectrum of tool and workpiece combinations. Simultaneously the improvements have to be implemented into a user-friendly software tool. Finally, this tool shall be able to simulate tool wear of coated and uncoated tools effectively. Therefore, the dialog based application will contain calibration data and models for several use cases and a tool wear assistant in order to support the user to calibrate additional tool and workpiece combinations.