ON NUMERICAL STRATEGY FOR TOOL WEAR MODELLING DURING AISI 4140 CUTTING

International audienceThe quality of machined products is strongly related to the machining conditions especially the tool wear evolution. The latter is among the most important problems encountered by manufacturers. In fact, the complexity of dealing with tool wear is due to the diversity of its origins (abrasion, diffusion, adhesion…) and the limits of models to predict it.For that, the majority of studies were based on experimental works to find laws linking tool wear to several cutting conditions [1, 2]. These estimations are limited to specific cutting conditions far from the industrial context. Some researchers resort to Finite Element (FE) Method to simulate cutting tool wear since it can help to investigate it finely than via experiment’s procedure [3, 4].The aim of this study is to develop a numerical model to simulate cutting tool wear via the FE software ABAQUS®. It is focused on the modeling of the machining of AISI 4140 steel by an uncoated tungsten carbide tool in an orthogonal cutting configuration.A multi-part model is developed to simulate tool wear in orthogonal cutting machining of AISI 4140 steel by an uncoated tungsten carbide tool. A new procedure helping to develop tool wear is implemented via Archard Law. The simulation results are validated by experimental tests