Thermodynamic modeling framework for prediction of tool wear and tool protection phenomena in machining

Axel Bjerke, Andrii Hrechuk, Filip Lenrick, Andreas Markström, Henrik Larsson, Susanne Norgren, Rachid M'Saoubi, Thomas Björk, Volodymyr Bushlya

Forskningsoutput: TidskriftsbidragArtikel i vetenskaplig tidskriftPeer review

Sammanfattning

Chemical, oxidational and diffusional interactions between the tool, chip and cutting environment are known tool wear mechanisms in machining. However, the interaction between tool, coating, workpiece, coolant and atmospheric oxygen can, under favorable conditions, lead to formation of reaction products that retard tool wear. A method with the ability to predict theses interactions, would therefore enable a better control over tool life in machining. An attempt to create such a modelling framework is developed in this study. This method can predict the phase composition and the driving force for degradation and the formation of protective interaction products in the cutting zone. This modeling approach is applicable across cutting processes in which chemical, diffusional and oxidational wear are dominant or present. This framework has been applied to investigate the interactions occurring in the cutting zone during turning of a medium alloyed low-carbon steel (Hybrid Steel® 55). A range of degradation events are predicted, as well as the formation of a protective corundum (Al,Fe,Cr)2O3 or spinel (Al,Fe,Cr)3O4 film due to an interaction between the Al-alloyed steel and the environment. Validation of the modeling was performed by studying tool wear and reaction products formed when machining with ceramics, PcBN and coated carbide tooling. Inserts are studied by the use of scanning and transmission electron microscopy, after cutting tests were performed. Additional tests were performed in different environments (dry, argon and coolant). The results confirmed the model predictions of oxidation and diffusion wear as well as the formation of an (Al,Fe,Cr)3O4 tool protection layer. Thus, the proposed thermodynamic framework seem promising to serve as a predictive instrument for the correct pairing of existing tool and workpiece combinations and cutting parameters, or for tailoring respective material compositions for intentional formation of a tool protection layer. As well as guidance on how to apply present and future kinetic models when concurrent interaction mechanisms are present. Which lead to a reduction and minimization of costly experimental machining tests.

Originalspråkengelska
Artikelnummer203991
TidskriftWear
Volym484-485
DOI
StatusPublished - 2021 nov 15

Bibliografisk information

Funding Information:
This work was funded by the national strategic innovation program − national action for Metallic Materials, organized by Vinnova and Jernkontoret (Sweden) under the DEMO project (ID 2017-02915 ). The authors would like to acknowledge the Sustainable Production Initiative (SPI) – a cooperation between Lund University and Chalmers University of Technology. This acknowledgment also extends to Per Alm and Vyacheslav Kryzhanivskyy (Seco Tools AB) for their help with IR thermography.

Funding Information:
This work was funded by the national strategic innovation program ? national action for Metallic Materials, organized by Vinnova and Jernkontoret (Sweden) under the DEMO project (ID 2017-02915). The authors would like to acknowledge the Sustainable Production Initiative (SPI) ? a cooperation between Lund University and Chalmers University of Technology. This acknowledgment also extends to Per Alm and Vyacheslav Kryzhanivskyy (Seco Tools AB) for their help with IR thermography.

Publisher Copyright:
© 2021 The Authors

Copyright:
Copyright 2021 Elsevier B.V., All rights reserved.

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