Modeling Flank Wear Progression Based on Cutting Force and Energy Prediction in Turning Process

Flank wear of cutting tools is often used as the tool life criterion because it has high impact on the diametric accuracy of turning. Accurate prediction of tool wear is important for optimizing tool change and other cutting parameters. In this work, a tool wear model is proposed based on the prediction of the cutting force and the energy consumption in turning process. Based on the cutting force prediction using a validated mechanistic force model, the energy consumption in turning can be estimated. A tool flank wear model is developed using the prediction of the cutting energy consumption and considering the impact of the cutting speed. By using the distribution of the cutting force on tool edge and the energy consumption for each revolution of the workpiece, the wear volume distribution on the tool edge for each revolution is predicted. The flank wear (VB) is further calculated using the tool geometry information. The model prediction of flank wear is validated by using tool wear data published in literature. The comparison shows that the model prediction agrees well with the experimental results.