Research on Tool Wear Based on 3D FEM Simulation for Milling Process

Abstract

In the process of metal cutting, the anti-wear performance of the tool determines the life of the tool and affects the surface quality of the workpiece. The finite element simulation method can directly show the tool wear state and morphology, but due to the limitations of the simulation time and complex boundary conditions, it has not been commonly used in tool life prediction. Based on this, a tool wear model was established on the platform of a finite element simulation software for the cutting process of titanium alloy TC4 by end milling. The key technique is to embed different types of tool wear models into the finite element model in combination with the consequent development technology. The effectiveness of the tool wear model was validated by comparing the experimental results with the simulation results. At the same time, in order to quickly predict the tool life, an empirical prediction formula of tool wear was established, and the change course of tool wear under time change was obtained.