A Combined Empirical and Numerical Approach for Tool Wear Prediction in Machining

In the present paper a combined empirical-numerical (finite element) approach for predicting the tool life has been introduced. This approach is based on the similarities found among the worn cutting edge geometries which have been obtained from the orthogonal tool life tests at different cutting speeds. The main difference between the proposed approach and those used in other finite element based tool wear prediction attempts is the lower computational time. Based on this approach finite element simulations of the cutting process based on worn tool geometries at several stages during the cut are run in parallel and provide the influential parameters on wear rate. Employing these parameters as input in the three well-known empirical wear rate equations, the relation between flank wear and cutting time are estimated. Predictions show agreement with experiment in terms of trend while some deviations exist in terms of the estimated magnitudes.