Development of a simulation based method for a load dependent optimisation of cemented carbide tools for nickel-base alloys - Variable micro geometry along the cutting edge

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This knowledge transfer project proposal is based on the fundamental research project: Modelling of the thermo-mechanical loads and wear behavior for optimisation of cemented carbid twist drills. The former project focused on the three-dimensional FE-simulation of chip formation for the prediction of the influence of the cutting edge preparation on the tool load during drilling processes. The low spatial resolution and long calculation times lead to difficulties during the analysis of the simulation. Therefore, an alternative model was proposed. These simulations of orthogonal cutting are carried out, which represent different orthogonal cut on the first primary cutting edge of a drilling tool. This technique offered the advantage of higher spatial resolution and shorter calculation times and should be applied and extended for drilling and milling of nickel-base alloys. This includes the consideration of local process conditions like the radius-dependent cutting speed in drilling by using design of experiments. The tool wear is simulated by the model of Usui. The parametric description of the cutting edge can be used for the statistical modelling of the tool wear which provides a wear prediction for every possible combination of parameter values. Furthermore, the statistical model is used to find cutting edge parameters which minimize the tool wear. This approach is extended here to milling processes, which have characteristic variations of the uncut chip thickness during a single tool rotation. Furthermore, a method is developed for measuring prepared cutting edges. Finally, optimized tools are compared to standard tools in experimental tests.