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A novel finite element method for the wear analysis of cemented carbide tool during high speed cutting Ti6Al4V process

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Abstract

In the present research, three typical cutting tool wear mechanisms (abrasive wear, adhesive wear, and diffusive wear) were taken into consideration in the FE simulation of cutting tool with a specific user-defined subroutine. Based on the influence of temperature on the cutting tool wear form, a novel wear rate model was built integrating Usui, Takeyama, and Attanasio wear rate equation. The high-speed cutting tests were carried out on Ti6Al4V to determine the proposed wear rate model constant. The cutting forces and rack face wear morphologies obtained from FE simulation match well with those from experimental cutting tests. Finally, the effect of cutting parameters on tool wear was studied by FEM. The simulation results show that the impact of the cutting speed on the cutting tool life is more significant than that of feed rate, and the preferred ranges of cutting speed and feed rate for extending cemented carbide cutting tool in high-speed dry cutting Ti6Al4V are 90–150 m/min and 0.10–0.20 mm/r, respectively.

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Funding

The authors gratefully acknowledge the financial supports of the National Natural Science Foundation of China (No. 51275231), the Anhui Provincial Natural Science Foundation (NO. 1608085ME121), and Nanjing University of Aeronautics and Astronautics PhD short-term visiting scholar project (No. 190304DF06).

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Authors and Affiliations

  1. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, People’s Republic of China

    Yang Wang, Honghua Su & Jianbo Dai

  2. College of Mechanical Engineering, Anhui University of Technology, Maanshan, 243000, People’s Republic of China

    Shubao Yang

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  1. Yang Wang
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  2. Honghua Su
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  3. Jianbo Dai
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  4. Shubao Yang
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Correspondence to Honghua Su.

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Wang, Y., Su, H., Dai, J. et al. A novel finite element method for the wear analysis of cemented carbide tool during high speed cutting Ti6Al4V process. Int J Adv Manuf Technol 103, 2795–2807 (2019). https://doi.org/10.1007/s00170-019-03776-1

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