Modelling of cutting process dynamics and tool wear prediction in turning

Abstract

The turning process is always accompanied by vibrations from the tool and spindle assembly, which directly influence on the surface quality and tool wear. At the same time, tool wear and vibrations are in a nonlinear relationship, causing mutual influence on each other. The paper proposes to model the dynamics of the cutting process taking into account the influence of elastic deformation displacements of the tool, perturbing vibration effects and the evolution of tool wear depending on the power trajectory of irreversible transformations. The aim of the study is to improve the efficiency of the turning process based on the identification of critical tool wear using a numerical simulation model. The simulation results are compared with experimental data from durability tests on a workpiece made of high-alloy heat-resistant steel. The vibration activity of the tool during the transition from the area of stabilisation of the cutting process to the zone of intensification of tool wear is analysed for simulation and experimental.