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Toward a better understanding of tool wear effect through a comparison between experiments and SPH numerical modelling of machining hard materials

Calamaz, Madalina and Limido, Jérôme and Nouari, Mohammed and Espinosa, Christine and Coupard, D. and Salaün, Michel and Girot, F. and Chieragatti, Rémy Toward a better understanding of tool wear effect through a comparison between experiments and SPH numerical modelling of machining hard materials. (2009) International Journal of Refractory Metals & Hard Materials, vol. 3 (n° 3). pp. 595-604. ISSN 0958-0611

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Official URL: http://dx.doi.org/doi:10.1016/j.ijrmhm.2008.09.005

Abstract

The aim of this study is to improve the general understanding of tungsten carbide (WC–Co) tool wear under dry machining of the hard-to-cut titanium alloy Ti6Al4V. The chosen approach includes experimental and numerical tests. The experimental part is designed to identify wear mechanisms using cutting force measurements, scanning electron microscope observations and optical profilometer analysis. Machining tests were conducted in the orthogonal cutting framework and showed a strong evolution of the cutting forces and the chip profiles with tool wear. Then, a numerical method has been used in order to model the machining process with both new and worn tools. The use of smoothed particle hydrodynamics model (SPH model) as a numerical tool for a better understanding of the chip formation with worn tools is a key aspect of this work. The redicted chip morphology and the cutting force evolution with respect to the tool wear are qualitatively compared with experimental trends. The chip formation mechanisms during dry cutting process are shown to be quite dependent from the worn tool geometry. These mechanisms explain the high variation of the experimental and numerical feed force between new and worn tools.

Item Type:Article
Additional Information:Thanks to Elsevier editor. The definitive version is available at http://dx.doi.org/doi:10.1016/j.ijrmhm.2008.09.005
Audience (journal):International peer-reviewed journal
Uncontrolled Keywords:
Institution:Other partners > Université Henri Poincaré-Nancy1 - UHP (FRANCE)
Université de Toulouse > Institut Supérieur de l'Aéronautique et de l'Espace - ISAE
Other partners > Arts et Métiers ParisTech (FRANCE)
French research institutions > Centre National de la Recherche Scientifique - CNRS
Other partners > Institut National Polytechnique de Lorraine - INPL (FRANCE)
Other partners > Ecole Nationale Supérieure des Mines de Nancy - ENSMN (FRANCE)
Other partners > Université de Bordeaux 1 (FRANCE)
Laboratory name:
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Deposited By: ESPINOSA Christine

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