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Tool wear prediction at different cutting edge locations for ball-end cutter in milling of Ni-based superalloy freeform surface part

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Abstract

Ni-based superalloy is one of the commonly used materials in the aerospace manufacturing field. Tool wear is inevitable and severe in machining Ni-based superalloy. The participation of worn tools in the machining process will lower the surface quality and increase production costs. These unacceptable results can be avoided if the worn tool gets a timely replacement with help of predicting the tool wear. Ball-end cutters are often used in semi-finishing or finishing freeform surface parts. However, the wear distribution along the cutting edge is uneven due to the hemisphere structure of the ball-end cutter and time-varying cutter-workpiece engagement. This phenomenon is hardly considered in existing prediction methods which predict a single value as the overall tool wear. Actually, a failure at any point on the cutting edge will reduce the overall cutting performance of the tool and degrade the surface integrity. Therefore, it is necessary to predict the wear distribution in the ball part. To fill the research gap, this study presents a tool wear prediction method, considering the variety of wear rates and cutting lengths along the cutting edge. First, an improved tool wear rate model considering the effect of the cutting edge location is established. Secondly, the cutting length distribution along the cutting edge is calculated by simulating the machining process. Finally, the wear of the cutting edge at each height is predicted by combining the corresponding wear rate and cutting length. The maximum wear on the tool flank is selected to represent the final tool wear state. The freeform surface milling experiment is carried out to validate this method. Results show that this method can predict the value and the position of the maximum wear on the tool flank under fixed cutting parameters. The prediction error of the maximum wear value is 12.5% when the tool approaches the wear criterion.

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Abbreviations

CWE:

Cutter-workpiece engagement

ACS:

Active cutting strip

ICS:

Inactive cutting strip

\(h\) :

Cutting strip height, mm

\(v\) :

Cutting speed, mm/min

\({v}_{h}\) :

Cutting speed at the height h, mm/min

\(n\) :

Spindle speed, rpm

\(r\) :

Tool shank radius, mm

\(w\) :

Flank wear, mm

\(T\) :

Tool life, min

l :

Cutting length in T, mm

\({C}_{1}\), \({C}_{2}\) :

Constants in tool life model

\(f\) :

Feed rate per tooth, mm/z

\(z\) :

The number of tool teeth

\(\alpha\), \(\beta\), \(\gamma\) :

Coefficients in tool life model

\(\theta\) :

Inclination angle, deg

\(\omega\) :

Wear rate

\({w}_{0}\) :

Initial tool wear

\({l}_{0}\) :

Cutting length with initial tool wear, mm

\(\boldsymbol{\Omega }\) :

Wear rate matrix

\({\varvec{L}}\) :

Cutting length matrix

\({\varvec{W}}\) :

Wear matrix

\({{\varvec{n}}}_{\mathrm{w}}\) :

Normal vector of workpiece surface

\({{\varvec{T}}}_{\mathrm{a}}\) :

Tool axis vector

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Acknowledgements

The authors sincerely thank Mr. Huan Luo for his help in the experiment and Mr. Wuyang Sun for his help in the writing.

Funding

This study was co-supported by the National Natural Science Foundation of China (Grant No. 91860137) and the 111 project (Grant No. B13044).

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Authors and Affiliations

  1. Key Laboratory of High Performance Manufacturing for Aero Engine (Northwestern Polytechnical University), Ministry of Industry and Information Technology, Xi’an, 710072, People’s Republic of China

    Zhuang Mao, Ming Luo & Dinghua Zhang

  2. Engineering Research Center of Advanced Manufacturing Technology for Aero Engine, Ministry of Education, Northwestern Polytechnical University, Xi’an, 710072, People’s Republic of China

    Ming Luo & Dinghua Zhang

Authors
  1. Zhuang Mao
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  2. Ming Luo
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  3. Dinghua Zhang
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Contributions

Zhuang Mao: methodology, writing, experiment, and data curation. Ming Luo: methodology, writing — review and editing, and supervision. Dinghua Zhang: supervision.

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Correspondence to Ming Luo.

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Mao, Z., Luo, M. & Zhang, D. Tool wear prediction at different cutting edge locations for ball-end cutter in milling of Ni-based superalloy freeform surface part. Int J Adv Manuf Technol 120, 2961–2977 (2022). https://doi.org/10.1007/s00170-022-08790-4

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