Wear estimation of ceramic and coated carbide tools in turning of Inconel 625: 3D FE analysis

Examination of cutting tool wear by experimental approaches is too costly. The main objective of this work is to develop an accurate 3D finite element model to predict the tool wear of PVD-TiAlN coated carbide and ceramic inserts in turning of Inconel 625. Thus, the cutting tools with complex geometries are modeled. Usui wear rate model is used to estimate wear rate where its constant parameters are achieved based on the cutting tools and workpiece material. The verification tests showed that the predicted values are in good agreement with the experiments. Moreover, among the cutting parameters, the increase of depth of cut were found as the most effective factor on the generation of temperature and stresses on the tool faces.