Fundamentals of wear mechanisms and wear modelling for unsteady turning processes

• Applicant: Professor Dr.-Ing. Berend Denkena
• Subject Area: Metal-Cutting and Abrasive Manufacturing Engineering
• Term: since 2021
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 470846572

During machining, high thermo-mechanical stresses on the cutting wedge occur, which cause wear on the tool. Characteristic forms of wear are formed in this process. These forms of wear are influ-enced by the material pairing tool - material, the tool geometry and the process conditions. The stress on the cutting wedge during turning in continuous cut and stationary process control variables is almost constant, apart from wear effects. As a result, the wear in the area of the highest load on the cutting wedge spreads continuously. This can weaken the cutting wedge mechanically and lead to a cutting edge breakage, which means total failure of the tool and can cause significant damage to the workpiece. By using transient process control variables, the maximum load and the place where it acts can be changed over time. Preliminary studies for this project have shown that the tool life can be increased by up to 40% compared to stationary processes. However, there is little knowledge today about the influence of transient process control in machining processes on tool wear behaviour. A process design by means of existing wear models is not possible, since these assume a constant load over time. In the project applied for here, therefore, the basic relationships between the manipulated variables of non-stationary machining processes, the resulting load and the tool wear mechanisms caused by this are to be investigated.

• DFG Programme: Research Grants