Research Papers

Local Crater Wear Prediction Using Physics-Based Models

[+] Author and Article Information
Jorge A. Olortegui-Yume

Department of Mechanical Engineering, Michigan State University, East Lansing, MI 48824-1326olortegu@egr.msu.edu

Patrick Y. Kwon1

Department of Mechanical Engineering, Michigan State University, East Lansing, MI 48824-1226pkwon@egr.msu.edu


Corresponding author.

J. Manuf. Sci. Eng 132(5), 051007 (Sep 22, 2010) (9 pages) doi:10.1115/1.4002111 History: Received May 11, 2009; Revised June 02, 2010; Published September 22, 2010; Online September 22, 2010

A physics-based, pointwise model is developed to predict crater profiles of multilayer coated carbides after a series of turning experiments. Dissolution and abrasion mechanisms, which are identified to be the dominant wear mechanisms at the crater, are reformulated into a pointwise or local quantity to predict the crater profiles based on the temperature and pressure profiles from finite element (FE) simulations. The crater profiles predicted by the proposed model have to be adjusted, however, due to the creep deformation of the carbide substrate occurring under the machining conditions employed in our experiment. The crater predictions correlate pretty well with the crater profiles experimentally observed in the multilayer (TiNAl2O3TiCN) coated carbides until the wear front reached the middle of the Al2O3 layer. At this point, the Al2O3 coating undergoes the κ-to-α-phase transformation, which makes the wear prediction difficult due to substantial changes in the thermomechanical properties of the Al2O3 coating.

Copyright © 2010 by American Society of Mechanical Engineers
Topics: Wear
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Figure 1

(a) Temperature and pressure profiles and (b) coordinates location in a real insert (50 s cutting time)

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Figure 2

Wear in a local form

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Figure 3

Differentials of chip length sliding simultaneously over rake face elements

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Figure 4

The compound nature of the tool wear front

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Figure 5

The active wear zone

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Figure 6

Modeling of the wear rate in the transition layer

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Figure 7

(a) Optical view, (b) stylus profiler reading, and (c) SE image, EDS element mappings, and BSE image of one calotte on the tool surface

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Figure 8

(a)–(d) BSE images of crater wear and (e)–(h) BSE images of flank wear (19)

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Figure 9

DEKTAK 6 M crater profiles evolution 0–22 min parallel to MICE (mask not scaled in the horizontal direction) (19)

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Figure 10

(a) Interfacial temperature and (b) normal stress at rake face based on FE simulation

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Figure 11

(a) Experimental and (b) predicted crater profiles

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Figure 12

(a) SEM view of corner with 22 min cutting time, (b) optical view for the 22 min corner, and (c) CLSM topography of (b) (17)

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Figure 13

Plastic deformation of the tool cutting edge

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Figure 14

Crater profiles overlaid onto a mask mimicking tool plastic deformation: (a) 16 min, (b) 18 min, (c) 20 min, and (d) 22 min

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Figure 15

Effect of the stacking sequence on the wear rate

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Figure 16

Experimental crater wear profiles. RAW profile obtained from stylus profiler. A7-wavelet filtered profile up to the seven levels of decomposition (15). A11-wavelet filtered profile up to the eleven level of decomposition (17).



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