A model to predict tool failure due to chipping in machining via the microstructure-level finite element cutting process simulation is presented and applied to a wide variety of WC-Co tool materials. The methodology includes the creation of arbitrary microstructures comprised of WC and Co phases to simulate various grades of WC-Co alloys. Equivalent stress, strain, and strain energy are then obtained via orthogonal microstructure-level finite element machining simulations. A model was developed to predict the occurrence of tool failure based on the mixed mode fracture criterion. Turning experiments were conducted to validate the model and the results showed that the model predictions agree well with the observations from the experiments. The model was then employed to study the effects of microstructural parameters and feedrate on chipping and failure.
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August 2006
Technical Papers
Microstructure-Level Model for the Prediction of Tool Failure in WC-Co Cutting Tool Materials
Sunghyuk Park,
Sunghyuk Park
Graduate Research Assistant
Department of Mechanical and Industrial Engineering,
University of Illinois at Urbana-Champaign
, Urbana, IL 61801
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Shiv G. Kapoor,
Shiv G. Kapoor
Professor
Fellow ASME
Department of Mechanical and Industrial Engineering,
University of Illinois at Urbana-Champaign
, Urbana, IL 61801
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Richard E. DeVor
Richard E. DeVor
Professor
Fellow ASME
Department of Mechanical and Industrial Engineering,
University of Illinois at Urbana-Champaign
, Urbana, IL 61801
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Sunghyuk Park
Graduate Research Assistant
Department of Mechanical and Industrial Engineering,
University of Illinois at Urbana-Champaign
, Urbana, IL 61801
Shiv G. Kapoor
Professor
Fellow ASME
Department of Mechanical and Industrial Engineering,
University of Illinois at Urbana-Champaign
, Urbana, IL 61801
Richard E. DeVor
Professor
Fellow ASME
Department of Mechanical and Industrial Engineering,
University of Illinois at Urbana-Champaign
, Urbana, IL 61801J. Manuf. Sci. Eng. Aug 2006, 128(3): 739-748 (10 pages)
Published Online: January 20, 2006
Article history
Received:
August 11, 2005
Revised:
January 20, 2006
Citation
Park, S., Kapoor, S. G., and DeVor, R. E. (January 20, 2006). "Microstructure-Level Model for the Prediction of Tool Failure in WC-Co Cutting Tool Materials." ASME. J. Manuf. Sci. Eng. August 2006; 128(3): 739–748. https://doi.org/10.1115/1.2194233
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