Title: Modelling and evaluation of flank wear progression of coated carbide tools in turning hardened steels

Authors: Satish Chinchanikar; S.K. Choudhury

Addresses: Mechanical Engineering Department, IIT Kanpur, Kanpur-208016, U.P., India ' Mechanical Engineering Department, IIT Kanpur, Kanpur-208016, U.P., India

Abstract: In the present context of sustainable manufacturing, evaluation of the flank wear will be extremely valuable. Machining with a severely worn tool affects the dimensional accuracy, surface finish and replacing the tool well before its tool life affects the machining economy. With this view, in the present work, empirical models for flank wear progression in terms of cutting parameters and machining time are developed in turning of hardened steel at two different levels of hardness namely, 35 and 45 HRC using multi-layer TiCN/Al₂O₃/TiN coated carbide tool. The unknown coefficients in the models were obtained by minimising the least squares error between experimental and predicted flank wear values obtained at different time instants for various cutting conditions. The correlation coefficients, found close to 0.9, showed that the developed models are reliable and could be used effectively for evaluating the flank wear for the given tool and work material combinations and within the domain of the cutting parameters.

Keywords: machining; hardened steel; tool wear; coated carbide tools; empirical models; cutting conditions; turning; wear patterns; wear mechanisms; modelling; flank wear; sustainable manufacturing.

DOI: 10.1504/IJMTM.2013.058626

International Journal of Manufacturing Technology and Management, 2013 Vol.27 No.1/2/3, pp.4 - 17

Received: 23 Feb 2013
Accepted: 05 Sep 2013
Published online: 29 Apr 2014 *

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