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Three-Dimensional Measurement and Finite-Element Simulation for Tool Wear Estimation in Cutting of Inconel 718 Superalloy

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Abstract

As the application of nickel-based heat-resistant alloy, a difficult-to-cut material, increases in aerospace engine, gas turbine and automotive parts, tool wear is emerging as an important issue. In this paper, finite-element (FE) simulations and experimental approaches are presented to estimate the tool wear of coated tungsten carbide cutting tools in the orthogonal cutting of Inconel 718. A tool wear model depends strongly on the experimentally acquired wear rates, which are measured by cutting tests. A three-dimensional data-based measurement method was investigated, and the volume loss of the tools was obtained to measure the wear geometries accurately. FE simulations of the cutting process were performed to calibrate the tool wear model by predicting the tool–workpiece interface temperature and normal stress. The constants of the tool wear model, for which the temperature-dependent wear model and Usui’s wear model were applied, were determined by a hybrid approach using FE simulation and experimental results. The approach was validated by comparing the estimated values with the experimental data.

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Acknowledgements

This work was supported by the Ministry of Trade, Industry and Energy (MOTIE) of the Republic of Korea for the Machinery Industry Core Technology Development Project “Cutting tool data platform based on machining process monitoring for manufacturing field application” [Project No. 20012580].

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Authors and Affiliations

  1. Center for Advanced Cutting Tool and Machining, Daegu Mechatronics & Materials Institute, 3, Seongseogongdan- ro, Dalseo-gu, Daegu, 42715, Republic of Korea

    Il-Chae Yoon, Ik-Soo Kang, Jae-Young Heo & Je-Ryung Lee

  2. Manufacturing System R&D Group, Korea Institute of Industrial Technology, 89, Yangdaegiro-gil, Ipjang-myeon, Seobuk-gu, Cheonan-si, 31056, Chungcheongnam-do, Republic of Korea

    Kyung-Hee Park

  3. Advanced Materials Research Team, Daegu Mechatronics & Materials Institute, 3, Seongseogongdan-ro, Dalseo-gu, Daegu, 42715, Republic of Korea

    Yun-Chul Jung

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  1. Il-Chae Yoon
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Yoon, IC., Kang, IS., Park, KH. et al. Three-Dimensional Measurement and Finite-Element Simulation for Tool Wear Estimation in Cutting of Inconel 718 Superalloy. Int. J. Precis. Eng. Manuf. 25, 21–34 (2024). https://doi.org/10.1007/s12541-023-00902-8

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