A new model to predict the tool life in turning of titanium aluminides

Abstract

AbstractSeveral tool wear models for machining operations have been reported in the literature. However, most of them are capable of modeling only a part of the wear curve, designed for quasi-linear curves or need to be fitted by means of differential equations. In this research, a new analytical easy-to-use wear model is proposed, taking into consideration the geometry of the cutting insert and the influence of the cutting speed and the tool-workpiece contact stress. In addition, the effect of the critical machining time, relative to the tool degradation, has also been introduced. The wear model describes completely the wear curve, from the initial rapid wear stage to the thermal-activated wear rate acceleration. The constants and parameters of the equation are determined by cutting experiments from the cutting forces and flank wear registers under a variety of technological parameters. This model has been validated for turning process on Ti48Al2Cr2Nb aluminide with uncoated carbide tool under different cutting conditions, varying the cutting speed and the geometrical position of the tool. It has been demonstrated its suitability to predict tool life, according to a defined wear criterion.