FEM assisted optimization of the cutting edge micro shape for machining of nickel-base alloys
Marcel Tiffe, Institute of Machining Technology/ TU Dortmund, Dortmund, GermanyRobert Aßmuth, Institute of Machining Technology/ TU Dortmund, Dortmund, GermanyDirk Biermann, Institute of Machining Technology/ TU Dortmund, Dortmund, Germany
The micro shape of a cutting edge has a major impact on the machining process in terms of the tool life, the workpiece quality and the productivity. Therefore, extensive work was carried out in former research projects to identify proper cutting edge designs. Nevertheless, this was mainly conducted by empirical analysis of processes like drilling and milling. In order to reduce the development time and the financial effort, it is desired to predict the influence of the cutting edge micro shape on the tool wear and to increase the tool performance. The Finite Element Method (FEM) is a capable method to simulate static problems as well as transient processes like chip formation also with respect to serrated chip formation. Therefore, it is possible to access process variables like stresses and temperatures, which are necessary to calculate tool wear. During an ongoing work of the Institute of Machining Technology and industrial partners, the tool wear, when machining nickel-base Inconel 718, is predicted via chip formation simulations using different cutting edge micro shapes. These shapes are modeled by means of different characteristic parameters. The variation of cutting edge parameters reveals a great potential to decrease the wear progression. By applying modern design planning and analysis techniques, the optimization of the tool wear behaviour can be executed exclusively through computational work. Nevertheless, the findings of the FEM-assisted wear prediction must be validated by machining experiments.