New Tool-life Relationships for Machining Processes

Research Team: Principal Investigator: Professor I. S. Jawahir Sponsors: Ford Motor Company
Postdoctoral Researcher: K.C. Ee National Science Foundation
Graduate Students: Abhijit D. Kardekar Kentucky Science and Engineering Foundation
Xiqun Wang

Objectives Influence of Cutting Conditions on Tool-life for Different

• Develop a new methodology for characterizing tool-wear parameters in tool Chip-grooves and Tool Coatings
inserts for turning and milling operations through an experimental study of the
effect of chip flow on tool-wear progression
Tool-life Versus Cutting Speed(CNMG 432K)
• Establish the effects of cutting conditions, operation types, tool coatings and (f = 0.254 mm/rev, a = 2.54 mm and
chip-groove configurations on tool-wear and tool-life
Work material = 1037M Steel)
• Develop new tool-life relationships for turning and milling (face and end milling)
operations based on experimental work and a detailed analysis of machining
parameters, cutting conditions, work and tool material properties and tool
geometry
Tool-life Versus Feed
Measurable Tool-wear Parameters in a Grooved Tool for Turning (V = 274.32 m/min, a = 0.254 mm and
Work material = 1037M Steel)

VB flank wear
BW width of groove backwall wear
BL length of groove backwall wear
KT depth of groove backwall wear
SW width of secondary face wear Tool-life Versus Depth of Cut
SD depth of secondary face wear (V = 274.32 m/min, a = 0.254 mm and
N nose wear Work material = 1037M Steel)
NL1 notch wear length on main cutting edge
NW1 notch wear width on main cutting edge
NL2 notch wear length on secondary cutting edge
NW2 notch wear width on secondary cutting edge

A New Tool-life Relationship For Turning with Grooved Tools Validation of Current Tool-life Relationships for Milling Operations
1 Tool-life Equation where
New Tool-life Equation Wc
V  n V = cutting speed
T = T RW g  R  End Milling D = cutter diameter
V  = helix angle
K1 D δ
m 1/ n 5
fz = feed per tooth
where W is coating effect factor and W is chip-groove effect factor T = 1/ n 1/ n1 1/ n2 1/ n3 1/ n aa = axial depth of cut
c g
V f z a a ar z 4 ar = radial depth of cut
km
W g = n1 n 2 Face Milling
z = number of teeth
K1, K2 = tool-life constants
Where
Where,
f a n1, n2, n3, n4, n5 and m = empirical constants
m
k = bl K2 D
l = engaged cutting edge length T= 1/ n1 1/ n 1/ n
f = feed V 1/ n
fz a a 2 a r 3 z 1 / n4
a = depth of cut
m = machining operation effect factor (m = 1 for turning)
n1, n2 and b = empirical constants SEM Observation of Flank, Face and Nose Wear of
End Mill Tool Inserts

Tool-wear Patterns of Typical Grooved Tools for Turning

Work material = 4140 Steel, TiN Coated Carbide Tool Inserts

(V = 400 m/min, f = 2 m/min and a = 4 mm)
Tool-life (ISO standard: 0.8 mm localized flank wear) = 5 min. 54 sec.

Tool-wear Progression in Different Grooved Tool Inserts Work material = 4140 Steel, TiN Coated Carbide Tool Inserts
(V = 274 m/min, f = 0.25 mm/rev, a = 1.9 mm, tool coating: KC850) (V = 400 m/min, f = 1 m/min and a = 7 mm)
Tool-life (ISO standard: 0.8 mm localized flank wear) = 9 min. 8 sec.
Tool Deterioration Criteria Illustrations
Phenomena (mm)
Flank wear
0.5
Future Research Direction
(VB, uniform)
ISO Standards for Flank wear
• Develop a new methodology for characterizing tool-wear in end milling
Tool-life in Milling 0.8 • Develop a complete tool-life model for milling, which incorporates the effects of
(VB, localized) tool material, tool coating, tool geometry and machining parameters
Operations Face wear • Extend the new tool-life relationships to drilling operations
(Crater depth, KT) 0.1
• Form a universal tool-life model for all turning, milling and drilling processes