Study of the use of wear maps for assessing machining performance

Abstract

The method of using wear maps in assessing tool wear over a range of cutting conditions was presented by Lim et al. in 1993 for turning steel using high-speed steel (HSS) tools. Since then this approach has rarely been studied or critically reviewed. The use of reliable wear maps can aid in assessing the wear rate and wear mechanism of cutting tools over a feed rate to cutting velocity plane. The focus of this paper is on improving the integrity of such wear maps. Unified cutting tests were undertaken to explore the effect of two different grades of carbide tooling on wear performance within a range of recommended cutting conditions. The methodology for developing such maps, as well as the underlying assumptions, was critically reviewed in light of two new wear maps created for different carbide grades. Additionally, by utilising energy dispersive X-ray (EDX) analysis and wear patterns, the paper presents new evidence in support of mechanisms responsible for the safety zone. Understanding the wear mechanisms in the low tool wear zone is important for developing extended life tooling.