Thermomechanical modeling of flank wear in turning

Abstract

This research investigates the impact of cutting conditions and tool geometry on flank wear during turning. A thermomechanical model was developed while considering abrasion as the mechanism of wear. The proposed model validation was performed using experiments from the literature with an uncoated carbide tool while turning an AISI 1045 workpiece. Furthermore, a parametric study is conducted to investigate the impact of tool geometry parameters and cutting conditions on flank wear growth. Therefore, a robust regression model with an R² of 97.6% for tool life as a function of the most influential parameters is established. Results collected from analytical and regression models reveal a significant correlation between flank wear and cutting speed, feed rate, rake angle, and nose radius. It was found that cutting tool life enhancement requires a cutting tool with a higher nose radius and a positive rake angle, besides machining with controlled cutting speed and feed rate. Furthermore, it was shown that decreasing the edge direction angle reduces flank wear and extends the tool’s life. These findings underscore the need to consider tool geometry to optimize cutting performance and reduce wear-related issues. The study’s outcomes have practical implications for turning operations, enabling the selection and design of cutting tools. This approach might be used to extend tool life and reduce tooling costs, leading to more effective machining operations and enhanced productivity.