Research on Tool Wear Based on 3D FEM Simulation for Milling Process
Abstract
:1. Introduction
2. Compilation of Subprogram and Establishment of Milling Finite Element Simulation Model
2.1. Design of Subprogram for the Tool Abrasion Prediction
2.2. Establishment of Milling Simulation Model
2.2.1. Ti6Al4V Constitutive Model
2.2.2. Friction Model
2.2.3. Damage Model
2.2.4. Cuttings Separation Criterion
2.3. Grid Partition of Finite Element Model
2.4. Prediction of Tool Abrasion Course and Tool Service
3. Expression of Different Types of Tool Abrasion Loss
3.1. Adhesion Abrasion (AD)
3.2. Grains Abrasion (GA)
3.3. Diffusion Abrasion (DA)
4. Experimental Verification and Simulation Results
4.1. Milling Experiment Design
4.2. Milling Experimental Results
4.3. Discussion of Finite Element Simulation Results
4.3.1. Analysis of Temperature Field Results of Tool
4.3.2. Analysis of Tool Abrasion Results
- (1)
- Error caused by grid dimension: The grid dimension decides the simulation precision. Oversized grid is difficult to guarantee the simulation precision and undersized grid causes an overly long simulation time. Hence, the appropriate grid dimension shall be selected after comprehensive consideration.
- (2)
- Milling vibration factors are not considered in the established simulation process of finite element simulation model.
- (3)
- The tool abrasion caused due to tipping is not considered in simulation process, and the tool Mises press is mainly observed to find tool tripping in the finite element simulation.
- (4)
- In the milling process of cemented carbide end mill, there is oxidation abrasion on its flank surface, but the oxidation abrasion is not considered in the abrasion prediction model.
5. Conclusions
- (1)
- On account of the change of tool abrasion type at different temperatures, the carbide cutter abrasion model considering temperature effect is constructed to avoid the limitation of single model and improve the prediction precision of the tool abrasion;
- (2)
- Combined the simulation results with the empirical formula, the tool abrasion course function can be calculated, which saves lots of simulation time and realizes the rapid prediction of the tool’s service life;
- (3)
- The test about on the service life of tool is carried out, and the simulation results and experiment measurement results are compared and analyzed. The simulation results can better simulate the change rules of tool abrasion in cutting process, and prediction error is within 30%, which can predict the service life of the tool to some extent.
Author Contributions
Funding
Acknowledgments
Conflicts of Interest
References
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Material | A/MPa | B/MPa | C | n | m |
---|---|---|---|---|---|
T6Al4V | 543.75 | 1363.6 | 0.127 | 0.33 | 0.303 |
d1 | d2 | d3 | d4 | d5 |
---|---|---|---|---|
−0.09 | 0.25 | −0.5 | 0.014 | 3.87 |
0.7573 | −7.277 | 3.2676 | 9.6475 | 8.3551 | 0.9567 |
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Liu, Z.; Yue, C.; Li, X.; Liu, X.; Liang, S.Y.; Wang, L. Research on Tool Wear Based on 3D FEM Simulation for Milling Process. J. Manuf. Mater. Process. 2020, 4, 121. https://doi.org/10.3390/jmmp4040121
Liu Z, Yue C, Li X, Liu X, Liang SY, Wang L. Research on Tool Wear Based on 3D FEM Simulation for Milling Process. Journal of Manufacturing and Materials Processing. 2020; 4(4):121. https://doi.org/10.3390/jmmp4040121
Chicago/Turabian StyleLiu, Zhibo, Caixu Yue, Xiaochen Li, Xianli Liu, Steven Y. Liang, and Lihui Wang. 2020. "Research on Tool Wear Based on 3D FEM Simulation for Milling Process" Journal of Manufacturing and Materials Processing 4, no. 4: 121. https://doi.org/10.3390/jmmp4040121