A framework for the physics-based estimation of tool wear in machining process
| Reference number | |
| Coordinator | CHALMERS TEKNISKA HÖGSKOLA AKTIEBOLAG - Material- och tillverkningsteknik |
| Funding from Vinnova | SEK 645 000 |
| Project duration | August 2017 - March 2018 |
| Status | Completed |
| Venture | The strategic innovation programme for Metallic material |
Purpose and goal
The main objective of the feasibility study was to develop physics-based tool wear modelling framework and assess if it is: (a) capable of predicting the influence of material variations due to chemical compositions (mainly variations in oxide/carbide/nitride content) on tool performance; (b) capable of predicting the tool wear response at various cutting conditions for a given tool/work material combination; (c) more robust compared to the alternative (e.g. process monitoring) approaches.
Expected results and effects
WEAR-FRAME results refer to R&D of innovative approaches/models for a more accurate/robust physics-based tool-wear prediction: (1) robust CALPHAD approach for solubility calculation of tool materials within various work materials; (2) DFT-based hardness estimations of non-metallic inclusions, carbides & nitrides at finite temperatures using Quasi-Harmonic Approximation (QHA); and (3) a hybrid approach for determination of flow stress properties of work materials at high strain rates & temperatures.
Planned approach and implementation
WEAR-FRAME included an extensive amount of experimental activity (machining tests) and material/tool characterisation to provide: (1) fundamental understanding of the wear mechanisms; (2) reliable data for development of the physics-based wear models.