Cross-scale identification method for friction damage on the tool flank of high-feed milling cutter

Due to high cutting speed and intermittent impact load, there exists significant friction and cutting vibration in milling process, which would lead to the mesoscopic friction damages. The friction damages and wear state thus become difficult to predict. In this work, the variation of instantaneous mechanical behavior of the milling cutter flank under vibration was studied. The structural deformation and friction damages of milling cutter flank in macro/mesoscopes were analyzed by conducting both thermal stress coupling field and molecular dynamic analysis. The multi-scale characterization method of instantaneous friction damage on cutter flank was proposed. The super-cell model of the tool-workpiece on the tool flank was developed. The variation of super-cell configuration was obtained. The nucleation and propagation of friction damages were identified; the evolution of mesoscopic friction damages on tool flank were revealed. The mesoscopic friction damage evolution of different positions on tool flank was researched; the coupling and competition mechanisms between the nucleation and propagation process of friction damages were unveiled. The cross-scale identification method of the friction damages of tool flank was validated by experiments.