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Too Sharp for its Own Good – Tool Edge Deformation Mechanisms in the Initial Stages of Metal Cutting

Laakso, S.V.A. LU ; Zhao, T. LU ; Agmell, M. LU ; Hrechuk, A. LU and Ståhl, J.-E. LU (2017) In Procedia Manufacturing 11. p.449-456
Abstract
© 2017 Metal cutting simulations have become an important part of cutting tool design and the research in the field in general. One of the most important aspects of modeling is the accuracy of the tool geometry. 3D microscopy is used for measuring the tool edge radius with good accuracy. However, especially with sharp tools, i.e. small tool edge radii, the measurements, no matter how accurate, are not much of a use, since the initial wear, or deformation is so fast in the first 1-30 seconds into the cutting, that the tool geometry is significantly different than the one measured from the new tool. The average tool life is often set to 15 minutes. Therefore, the cutting simulations that only predict the tool behavior in the first seconds of... (More)
© 2017 Metal cutting simulations have become an important part of cutting tool design and the research in the field in general. One of the most important aspects of modeling is the accuracy of the tool geometry. 3D microscopy is used for measuring the tool edge radius with good accuracy. However, especially with sharp tools, i.e. small tool edge radii, the measurements, no matter how accurate, are not much of a use, since the initial wear, or deformation is so fast in the first 1-30 seconds into the cutting, that the tool geometry is significantly different than the one measured from the new tool. The average tool life is often set to 15 minutes. Therefore, the cutting simulations that only predict the tool behavior in the first seconds of its lifetime are not very useful in predicting the process variables throughout the tool life. Simulations with creep and elastic-plastic material model however, can predict the initial deformation of the tool. This tool shape can be then used in rigid tool model to predict the process variables in the steady wear region of the tool life. This paper presents simulation model for predicting the initial tool edge deformation for WC-10%Co tool while machining AISI 304 stainless steel. The novelty in this approach is the simultaneous coupled calculation of contact surface temperature and stress and change of the tool shape. (Less)
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author
organization
publishing date
type
Contribution to journal
publication status
published
subject
keywords
AISI 304, Carbide, Creep, FEM, Johnson-Cook, Metal Cutting, Plastic Lowering of Tool Edge, Turning, WC-10%Co
in
Procedia Manufacturing
volume
11
pages
449 - 456
publisher
Elsevier
external identifiers
  • scopus:85019565468
DOI
language
English
LU publication?
yes
id
eca2c856-ed9b-4987-8fa7-9035124477f3
date added to LUP
2018-04-06 12:49:51
date last changed
2018-06-10 05:27:59
@article{eca2c856-ed9b-4987-8fa7-9035124477f3,
  abstract     = {© 2017 Metal cutting simulations have become an important part of cutting tool design and the research in the field in general. One of the most important aspects of modeling is the accuracy of the tool geometry. 3D microscopy is used for measuring the tool edge radius with good accuracy. However, especially with sharp tools, i.e. small tool edge radii, the measurements, no matter how accurate, are not much of a use, since the initial wear, or deformation is so fast in the first 1-30 seconds into the cutting, that the tool geometry is significantly different than the one measured from the new tool. The average tool life is often set to 15 minutes. Therefore, the cutting simulations that only predict the tool behavior in the first seconds of its lifetime are not very useful in predicting the process variables throughout the tool life. Simulations with creep and elastic-plastic material model however, can predict the initial deformation of the tool. This tool shape can be then used in rigid tool model to predict the process variables in the steady wear region of the tool life. This paper presents simulation model for predicting the initial tool edge deformation for WC-10%Co tool while machining AISI 304 stainless steel. The novelty in this approach is the simultaneous coupled calculation of contact surface temperature and stress and change of the tool shape.},
  author       = {Laakso, S.V.A. and Zhao, T. and Agmell, M. and Hrechuk, A. and Ståhl, J.-E.},
  keyword      = {AISI 304,Carbide,Creep,FEM,Johnson-Cook,Metal Cutting,Plastic Lowering of Tool Edge,Turning,WC-10%Co},
  language     = {eng},
  pages        = {449--456},
  publisher    = {Elsevier},
  series       = {Procedia Manufacturing},
  title        = {Too Sharp for its Own Good – Tool Edge Deformation Mechanisms in the Initial Stages of Metal Cutting},
  url          = {http://dx.doi.org/},
  volume       = {11},
  year         = {2017},
}