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TECHNICAL PAPERS

Modeling the Progression of Flank Wear on Uncoated and Ceramic-Coated Polycrystalline Cubic Boron Nitride Tools in Hard Turning

[+] Author and Article Information
Ty G. Dawson

 Milliken Research Corporation, P. O. Box 1927, M-405, Spartanburg, SC 29303ty.dawson@milliken.com

Thomas R. Kurfess

George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, MARC 435, Atlanta, GA 30332-0405kurfess@me.gatech.edu

J. Manuf. Sci. Eng 128(1), 104-109 (Dec 22, 2004) (6 pages) doi:10.1115/1.2039097 History: Received August 05, 2003; Revised December 22, 2004

Accurate wear modeling has always been desired, but has also been difficult and elusive. Most useful wear models have relied on experimental calibration because the physical wear mechanisms are not fully understood. This is particularly true in machining, where contact stresses and temperatures can be extremely high. In machining, the two wear modes most frequently discussed are crater wear and flank wear. Flank wear receives much more attention because it is easier to measure and the mechanism of material loss is thought to be better understood for most machining situations. This work focuses on flank wear for the same reasons. In hard turning, tool life is relatively short and both crater wear and flank wear influence the cutting process substantially. Understanding the progression of flank wear at various cutting conditions is beneficial in itself, but the ability to predict this progression will be extremely valuable. This work addresses both. Experimental flank wear progression is shown for uncoated and ceramic-coated polycrystalline cubic boron nitride (PCBN) tools at a range of cutting conditions. These data are used to calibrate a proposed mechanical wear model that predicts the progression of flank wear and tool failure points based on the cutting speed, feed, and cutting depth. The model was validated by additional experiments, which show good agreement with the predictions.

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Copyright © 2006 by American Society of Mechanical Engineers
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Figures

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Figure 1

Two-dimensional view of the cutting process

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Figure 2

Cross-sectional view of tool tip showing worn area due to flank wear

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Figure 3

Crater wear (top) and flank wear (front) on a PCBN cutting tool

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Figure 4

Modeled flank wear progression and experimental results

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Figure 5

Modeled flank wear progression and experimental results

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Figure 6

Measurement of the size of flank land

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Figure 7

Top view of cutting tool engaged with the workpiece

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Figure 8

Predicted flank wear progression and failure points for uncoated tools

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Figure 9

Predicted flank wear progression and failure points for coated tools

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Figure 10

Predicted behavior compared to validation test data

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