Cutting tool fracture prediction and strength evaluation by stress identification, part i: Stress model

doi:10.1016/S0890-6955(97)00031-X

International Journal of Machine Tools and Manufacture

Volume 37, Issue 12, December 1997, Pages 1691-1714

https://doi.org/10.1016/S0890-6955(97)00031-X Get rights and content

Abstract

Cutting tool premature failure, caused by tool fracture and chipping, is a frequent problem in the metal cutting area. For a certain type of cutting tool, correctly identifying its load profile and property profile is very crucial for prediction of the tool premature failure. The most direct way to evaluate the load profile and property profile of a cutting tool is to identify the stress working on it. This paper presents a new method for identification of the maximum principal stress and maximum effective stress subjected to a cutting tool in a cutting process. The method consists of four steps: estimation of the contact load on the tool faces, calculation of the maximum related stresses with the FEM, modelling of maximum related stresses with an artificial neural network and, finally, identification of the maximum principal stress, σ_e, and maximum effective stress, σ_e, with the use of measured cutting forces or cutting parameters. The calculation of the contact load on the tool face is based on a simplification of the load distribution on the tool face. Part I of the paper will present this method and Part II will present the results of experimental studies.

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The model was not able to predict the stress distribution in the regions close to the tool tip due to the uniformly distributed loads. One of the early studies by Zhou et al. [12] presented a method for identification of the maximum principal stress and maximum effective stress subjected to a cutting tool in turning processes. An FEM model was developed with varying distributed load based on Zorev’s work [13] applied to the rake and flank faces of the turning insert.
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Cutting tool fracture prediction and strength evaluation by stress identification, part i: Stress model

Abstract

Annals of the CIRP

International Journal of Machine Tools Manufacture

Tool fracture probability under steady state cutting condition

Journal of Engineering for Industry

Interrupted cutting with brittle tools

Definition and measurement of strength and toughness behaviour of carbides

Disturbances in cutting process caused by edge deterioration

Chipping and breakage of carbide tools

Journal of Engineering for Industry

Analytical prediction of entry-chipping in interrupted turning operation