A First Step towards a Tribological Approach to Investigate Cutting Tool Wear

Abstract:

The present work is motivated by the will to improve Finite Element (FE) Modelling of cutting tool wear. As a first step, the characterisation of wear mechanisms and identification of a wear model appear to be fundamental. The key idea of this work consists in using a dedicated tribometer, able to simulate relevant tribological conditions encountered in cutting (pressure, velocity). The tribometer can be used to estimate the evolution of wear versus time for various tribological conditions (pressure, velocity, temperature). Based on this design of experiments, it becomes possible to identify analytically a wear model. As a preliminary study this paper will be focused on the impact of sliding speed at the contact interface between 304L stainless steel and tungsten carbide (WC) coated with titanium nitride (TiN) pin. This experiment enables to observe a modification of wear phenomena between sliding speeds of 60 m/min and 180 m/min. Finally, the impact on macroscopic parameters has been observed.

• Periodical: Key Engineering Materials (Volumes 611-612)
• Pages: 452-459
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.611-612.452
• Online since: May 2014
• Authors: Giovenco Axel*, Frédéric Valiorgue, Cédric Courbon, Joël Rech, Ugo Masciantonio
• Keywords: Cutting, Friction, Heat Partition, Wear

References

[1] G. Byrne, D. Dornfeld, and B. Denkena. Advancing cutting technology. CIRP Annals - Manufacturing Technology, 52(2): 483 - 507, (2003).

DOI: 10.1016/s0007-8506(07)60200-5

[2] I. Arriola, E. Whitenton, J. Heigel, and P.J. Arrazola. Relationship between machinability index and in-process parameters during orthogonal cutting of steels. CIRP Annals - Manufacturing Technology, 60(1): 93 - 96, (2011).

DOI: 10.1016/j.cirp.2011.03.082

[3] R. M'Saoubi and H. Chandrasekaran. Experimental study and modelling of tool temperature distribution in orthogonal cutting of aisi 316l and aisi 3115 steels. The International Journal of Advanced Manufacturing Technology, pages 1-13, 2011. 10. 1007/s00170-011-3257-y.

DOI: 10.1007/s00170-011-3257-y

[4] P.J. Arrazola, I. Arriola, M.A. Davies, A.L. Cooke, and B.S. Dutterer. The effect of machinability on thermal fields in orthogonal cutting of AISI 4140 steel. CIRP Annals - Manufacturing Technology, 57(1): 65 - 68, (2008).

DOI: 10.1016/j.cirp.2008.03.139

[5] T. Ozel. Finite element simulation of machining nickel-based alloy in the presence of tool flank wear. In Proceedings of the 12th CIRP Conference on Modelling of Machining Operations, Donostia-San Sebastian, Spain, (2009).

[6] Thomas Childs, Katsuhiro Maekawa, Toshiyuki Obikawa, and Yasuo Yamane. 4 - tool damage. In Thomas Childs, Katsuhiro Maekawa, Toshiyuki Obikawa, and Yasuo Yamane, editors, Metal Machining, pages 118 - 135. Butterworth-Heinemann, Oxford, (2000).

DOI: 10.1016/b978-0-08-052402-3.50007-1

[7] E. Usui, T. Shirakashi, and T. Kitagawa. Analytical prediction of three dimensional cutting process - part 3 : Cutting temperature and crater wear of carbide tool. Journal of Engineering for Industry, Transactions of ASME, 100: 236 - 243, (1978).

DOI: 10.1115/1.3439415

[8] J. F. Archard. Contact and rubbing of flat surfaces. Journal of Applied Physics, 24: 981 - 988, (1953).

DOI: 10.1063/1.1721448

[9] H. Takeyama and T. Murata. Basic investigations on tool wear. Journal of Engineering for Industry, Transactions of ASME, 85: 33 - 38, (1963).

[10] A. Attanasio, E. Ceretti, A. Fiorentino, C. Cappellini, and C. Giardini. Investigation and fembased simulation of tool wear in turning operations with uncoated carbide tools. Wear, 269(5- 6): 344 - 350, (2010).

DOI: 10.1016/j.wear.2010.04.013

[11] L. Filice, D. Umbrello, S. Beccari, and F. Micari. On the fe codes capability for tool temperature calculation in machining processes. Journal of Materials Processing Technology, 174(1-3): 286 - 292, (2006).

DOI: 10.1016/j.jmatprotec.2006.01.012

[12] M. Olsson, B. Stridh, S. Soderberg, and U. Jansson. Sliding wear of hard materials - the importance of a fresh countermaterial surface. Wear, 124(2): 195 - 216, (1988).

DOI: 10.1016/0043-1648(88)90244-x

[13] C. Claudin, A. Mondelin, J. Rech, and G. Fromentin. Effects of a straight oil on friction at the tool-workmaterial interface in machining. International Journal of Machine Tools and Manufacture, 50(8): 681 - 688, (2010).

DOI: 10.1016/j.ijmachtools.2010.04.013

[14] J. Rech, P.J. Arrazola, C. Claudin, C. Courbon, F. Pusavec, and J. Kopac. Characterisation of friction and heat partition coefficients at the tool-workmaterial interface in machining. CIRP Annals Manufacturing Technology, 62(1): 79 - 82, (2013).

DOI: 10.1016/j.cirp.2013.03.099

[15] O. Klinkova, J. Rech, S. Drapier, and J. -M. Bergheau. Characterization of friction properties at the workmaterial/cutting tool interface during the machining of randomly structured carbon fibers reinforced polymer with carbide tools under dry conditions. Tribology International, 44(12): 2050 - 2058, (2011).

DOI: 10.1016/j.triboint.2011.09.006

[16] H.O. Gekonde and S.V. Subramanian. Tribology of tool-chip interface and tool wear mechanisms. Surface and Coatings Technology, 149: 151 - 160, (2002).

DOI: 10.1016/s0257-8972(01)01488-8

[17] J. Hwang and S. Chandrasekar. Contact conditions at the chip-tool interface in machining. International Journal of Precision Engineering and Manufacturing, 12: 183-193, 2011. 10. 1007/s12541-011-0026-7.

DOI: 10.1007/s12541-011-0026-7

[18] H. BenAbdelali. Caracterisation et modelisation des mecanismes tribologiques aux interfaces outils-pieces-copeaux en usinage a sec de l'acier C45. PhD thesis, Ecole Nationale d'Ingenieurs de Monastir / EC Lyon, (2013).

[19] C. Courbon. Vers une modelisation physique de la coupe des aciers speciaux : integration du comportement metallurgique et des phenomenes tribologiques et thermiques aux interfaces. PhD thesis, EC Lyon, (2011).

[20] F. Valiorgue, J. Rech, H. Hamdi, C. Bonnet, P. Gilles, and J.M. Bergheau. Modelling of friction phenomena in material removal processes. Journal of Materials Processing Technology, 201: 450 - 453, (2008).

DOI: 10.1016/j.jmatprotec.2007.11.266

[21] H. BenAbdelali, C. Courbon, J. Rech, W. Ben Salem, A. Dogui, and Ph. Kapsa. Identification of a friction model at the tool-chip-workpiece interface in dry machining of a aisi 1045 steel with a tin coated carbide tool. Journal of Tribology, 133(4): 042201, (2011).

DOI: 10.1115/1.4004879