TY - JOUR

T1 - FE-Simulation Based Design of Wear-Optimized Cutting Edge Roundings

AU - Bergmann, Benjamin

AU - Denkena, Berend

AU - Beblein, Sascha

AU - Picker, Tobias

N1 - Funding Information: Funding: This research was funded by the Deutsche Forschungsgemeinschaft (DFG), reference number DE447/71–2. The authors would also like to thank the “Sieglinde Vollmer Stiftung” for the financial support of this research work.

PY - 2021/12

Y1 - 2021/12

N2 - The performance of cutting tools can be significantly enhanced by matching the cutting edge rounding to the process and material properties. However, the conventional cutting edge rounding design is characterized by a significant number of experimental machining studies, which involve considerable cost, time, and resources. In this study, a novel approach to cutting edge rounding design using FEM-based chip formation simulations is presented. Based on a parameterized simulation model, tool temperatures, stresses and relative velocities can be calculated as a function of tool microgeometry. It can be shown that the external tool loads can be simulated with high agreement. With the help of these loads and the use of wear models, the resulting tool wear and the optimum cutting edge rounding can be determined. The final experimental investigations show a qualitatively high agreement to the simulation, which will enable a reduced effort design of the cutting edge in the future.

AB - The performance of cutting tools can be significantly enhanced by matching the cutting edge rounding to the process and material properties. However, the conventional cutting edge rounding design is characterized by a significant number of experimental machining studies, which involve considerable cost, time, and resources. In this study, a novel approach to cutting edge rounding design using FEM-based chip formation simulations is presented. Based on a parameterized simulation model, tool temperatures, stresses and relative velocities can be calculated as a function of tool microgeometry. It can be shown that the external tool loads can be simulated with high agreement. With the help of these loads and the use of wear models, the resulting tool wear and the optimum cutting edge rounding can be determined. The final experimental investigations show a qualitatively high agreement to the simulation, which will enable a reduced effort design of the cutting edge in the future.

KW - Cutting edge roundings

KW - FE simulation

KW - Wear simulation

UR - http://www.scopus.com/inward/record.url?scp=85121054028&partnerID=8YFLogxK

U2 - 10.3390/jmmp5040126

DO - 10.3390/jmmp5040126

M3 - Article

AN - SCOPUS:85121054028

VL - 5

JO - Journal of Manufacturing and Materials Processing

JF - Journal of Manufacturing and Materials Processing

IS - 4

M1 - 126

ER -