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RESEARCH PAPERS

Microstructure-Level Model for the Prediction of Tool Failure in Coated WC-Co Cutting Tool Materials During Intermittent Cutting

[+] Author and Article Information
Sunghyuk Park, Shiv G. Kapoor, Richard E. DeVor

Department of Mechanical Science and Engineering,  University of Illinois at Urbana-Champaign, Urbana, IL 61801

J. Manuf. Sci. Eng 129(5), 893-901 (Mar 29, 2007) (9 pages) doi:10.1115/1.2738507 History: Received December 01, 2006; Revised March 29, 2007

A model to predict failure of coated WC-Co grades due to chipping in intermittent cutting via microstructure-level finite element machining process simulation is presented and applied to various coated WC-Co tools. Coated tools were examined for the characterization and simulation of their microstructures. Model predictions of failure due to chipping for coated WC-Co systems were validated by continuous machining tests. In order to simulate cyclic loading conditions during intermittent cutting, mechanical and thermal boundary conditions were applied during cutting phases and removed during noncutting phases. Interrupted turning experiments were conducted to validate the model, and the results showed that the predictions agreed well with the observations from the experiments. The paper includes the application of this model to a problem of WC-Co grade design.

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Copyright © 2007 by American Society of Mechanical Engineers
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Figures

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Figure 2

Simulated tool microstructure with two coating layers over straight WC-Co substrate

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Figure 3

Hot hardness values of various hard coating materials

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Figure 4

(a) Length (l) and orientation angle (α′) of equivalent crack and (b) fracture locus drawn by using Eqs. 3,4(22)

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Figure 5

SEM images of cutting edges in KC730 grade (a) F=0.748 at 250μm feed rate (b) F=1.114 at 275μm feed rate

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Figure 6

Illustration of interrupted cutting simulation

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Figure 7

Change of crack length (li) and crack inclination angle (αi′) due to crack growth over successive cycles in intermittent cutting: (a) after first loading∕unloading cycle, (b) after tenth cycle, and (c) after twentieth cycle

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Figure 8

Comparison of time to fracture predicted using Eq. 6 with simulation up to F⩾1

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Figure 9

Schematic illustration of the procedure of tool failure prediction; shaded regions where F⩾1

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Figure 10

SEM images of chipped surfaces on the tool rake face near the cutting edge in interrupted turning: (a) KC730 at 150μm feed rate and (b) KC9245 at 250μm feed rate

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Figure 11

F values over a range of feed rates for KC730: solid line by extrapolation

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Figure 12

F values over a range of feed rates for KC9245: solid line by extrapolation

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Figure 1

Measurement of microstructural parameters; coating materials and thicknesses of each coating layer

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