Prediction of tool wearability distribution considering friction and energy characteristics of the cutting process

Abstract

The accurate assessment of tool wear characteristics is of paramount significance in digital manufacturing, as it directly influences machining efficiency, precision, and energy consumption. This study investigated the wearability distribution of cemented carbide tools during high-performance iron-based material machining by examining the friction and energy characteristics present in the tool-chip interaction. Initially, an analysis of the energy transfer and cumulative distribution within the tool-workpiece system was conducted, leading to the proposal of a wear mechanism that is deeply coupled with the diffusion heat energy density and friction energy power density. Subsequently, the correlation between the cumulative energy damage density and wear characteristics in various regions of the rake face is investigated, and the load distribution was calculated, considering bond damage. The findings revealed the presence of a third body layer during the bond damage process, and its viscoelastic properties significantly impacted the load distribution and damage behavior. A comprehensive wearability distribution model for the rake face was developed by leveraging insights obtained from the coupling mechanism and load characteristics. The model highlights substantial variations in the abrasive distribution across different locations on the rake face. The experimental results corroborate the general applicability and effectiveness of the proposed method, offering theoretical guidance for enhancing digital manufacturing processes.