Temperature, Tool Wear
Temperature, Tool Wear
Temperature, Tool Wear
Fig2.effect of cutting
speed V and cutting
time T on crater wear
depth KT
Is normally caused by:
Sliding of tool over work piece
Abrasion of hard particles
inclusion in the work piece.
Shearing of micro welds between
tool and work material.
Abrasion of fragments of built up
edge plowing against the
clearance face of the tool.
1. Initial (or Preliminary) wear region
Caused by micro-cracking, surface oxidation and
carbon loss layer, as well as micro-roughness at the
cutting tool tip in tool grinding (manufacturing).
2 Steady wear region
After the initial (or preliminary) wear (cutting
edge rounding), the micro-roughness isimproved,
in this region the wear size is proportional to the
cutting time. The wear rate is relatively constant.
3 Severe (or Ultimate or catastrophic) wear
When the wear size increases to a critical value,
the surface roughness of the machined surface
decreases, cutting force and temperature increase
rapidly, and the wear rate increases. Then the tool
loses its cutting ability.
NOTCH WEAR
oThe gashing (or grooving, gouging) at
the outer edge of the wear land is an
indication of a hard or abrasive skin on
the work material.
oSuch a skin may develop during the
first machine pass over a forging, casting
or hot-rolled workpiece.
oThis is a special type of combined flank
and rake face wear which occurs adjacent
to the point where the major cutting edge
intersects the work surface.
oIt is also common in machining of
materials with high work-hardening
characteristics, including many stainless
steels and heat-resistant nickel or
chromium alloys. In this case , the
previous machining operation leaves a
thin work-hardened skin.
EFFECTS OF TOOL WEAR
INFLUENCE ON CUTTING FORCES
The cutting forces are normally increased by wear of the tool.
Crater wear may, however, under certain circumstances, reduce forces by
effectively increasing the rake angle of the tool.
Clearance-face (flank or wear-land) wear and chipping almost invariably
increase the cutting forces due to increased rubbing forces.
SURFACE FINISH
The surface finish produced in a machining operation usually deteriorates
as the tool wears. This is particularly true of a tool worn by chipping and
generally the case for a tool with flank-land wear
there are circumstances in which a wear land may burnish (polish) the
workpiece and produce a good finish.
DIMENSIONAL ACCURACY
Flank wear influences the plan geometry of a tool; this may affect
the dimensions of the component produced in a machine with set
cutting tool position or it may influence the shape of the components
produced in an operation utilizing a form tool.
If tool wear is rapid, cylindrical turning could result in a tapered
workpiece
VIBRATION OR CHATTER
A wear land increases the tendency of a tool to dynamic instability.
A cutting operation which is quite free of vibration when the tool is
sharp, may be subjected to an unacceptable chatter mode when the
tool wears.
DETERMINING TOOL FAILURE
The cutting edge completely fails
Visual inspection of flank wear
Run fingernail across the cutting edge
Change of sound
Chip become difficult to dispose
Degradation of surface finish
Increase in power consumption