Abstract
The synchronous wear of the inner and outer inserts is vital for the indexable drill with stable high-performance stability throughout life. In this study, the finite element simulation model for the indexable drill is developed, in which the accurate material constitutive model considering the strain rate and thermal softening is established experimentally. The synchronous wear design of the inner and outer inserts is implemented based on finite element simulation. The initial radial force is optimized before the synchronous wear design. Then, the wear rates of inner and outer inserts are predicted based on the temperature and stress of tools extracted from the simulations and the classical wear model, which is used for the synchronous wear design. The results show that the calculated tool wear rates for inner and outer inserts are close to each other when the tool edge radius, rake angle and relief angle are 20 µm, 8° and 4°, respectively. The synchronous wear could also be achieved for different process parameters based on the optimized parameters of the insert.