A Novel Approach for Modelling Loads on Profiled Cutting Tools

Wear of cutting tools is known to affect the surface integrity of the workpiece and significantly contributes to machine downtime. Modelling the cutting process by means of Finite Element Analysis (FEA) yields advantages to gain insights in the loads applied on the cutting tool. For the process of profile grooving only 3D modeling approaches can be employed to capture the non-linear loads relevant for wear modelling. Caused by a transient cutting phase with changing cutting conditions, capturing the wear relevant state variables over the grooving process requires huge computational resources. Aiming to reduce the simulation time for profile grooving, a novel approach is presented which transferes the cutting process to an orthogonal cutting test bench with a significantly reduced workpiece length. Workpieces are prepared with a groove that matches the shape of the tool before preparing them with a ramp or a step to enable studying the grooving process for continuously changing cutting widths and a step for abruptly changing cutting widths to resemble the freedom of design of grooving tools. The proposed approach is validated by evaluating the mechanical loads of grooving operations conducted on a turning center, on the orthogonal cutting test bench and the corresponding 3D cutting simulations with two different tool shapes to study the approach with continuously and abruptly changing cutting widths. Results show a high similarity of the cutting experiments with the proposed modeling approach with a median absolute error of 7.3% on selected points of the grooving process while offering a reduced cutting distance of 99% over the turning operation. The results show, that the required computational resources for modeling profile grooving processes can significantly be reduced while keeping the loads on the tool within reasonable accuracy. The findings promise a more efficient approach for modelling loads on profiled cutting tools with possible applications in wear modeling.