Paper 2

THE INFLUENCE OF TOOL WEAR ON THE TURNING PROCESS

ACCURACY

I.

The purpose of the paper

The tool wear during cutting technologies is a complex process, influenced by several

factors: mechanical and thermal stresses, mechanical abrasion between chip tool and workpiece,
built-up edge, burnings, oxidations, etc. The main effects of tool wear are: poor surface finish,
increasing cutting forces, increasing cutting temperatures, decreased accuracy of final part, all
these may lead to tool breakage and cause changes in tool geometry.
The objective of this paper is to study the variation of the tool wear taking into account
the cutting length and the tool material quality.
II.

Theoretical considerations
In this paper the dimensional tool wear (u) on perpendicular direction to the processed

surface is analyzed. The tool wear on the rake face Crater wear(ud) and the flank face flank
wear (ua) determines the ability of cutting. In this case the wear on the rake face and the flank
face are not taken into consideration.

Fig.1. Cutting tool wear diagram, showing the main locations and types of wear that occur

a.

b.
Fig.2. (a) Crater wear, and (b) flank wear on a cemented carbide tool, as seen through a
toolmaker's microscope

The appearance of the wear on these two surfaces of the cutting tool is influenced by the
following factors: the processed material, tool material, cutting parameters (spindle speed, feed
rate and depth of processing), etc.
For manufacturing parts with high dimensional accuracy and good surface quality it is
important to understand the wear appearance and the possibility of determining it.

Fig.3. The dimensional tool wear(u)

Calculation of the dimensional tool wear using the next relation, u h tg gives errors up
to 40% because the main cutting edge is not always in top of the cutter, his position is changing
continuously during cutting. Therefore, the dimensional tool wear size must be determined using
special devices.
The dimensional tool wear as a function of cutting time has three distinct areas
(Fig. 4):

I Rapid initial wear (Break-in period); II Uniform wear rate (Steady-state wear region);
III Accelerating wear rate (Failure region).

Fig.4. The dimensional tool wear as a function of cutting time

The dimensional tool wear may be expressed in terms of cutting length, starting from

L v (1)
where: - cutting time [min]; v cutting speed [m/min]; L - cutting length [m].
In the diagram the tool wear as a function of the length cutting for carbide inserts (Figure 5)
are distinguished three areas: the rapid initial wear, the uniform wear rate and the accelerating
wear rate. The cutting length up to 1000 - 1500 m is the rapid initial wear. In the central part of
the graphic is observed the uniform wear rate, the normal wear zone, it can be considered a linear
and constant wear rate vu ct .

Fig. 5. The tool wear as a function of the length cutting for carbide inserts

To determine the dimensional tool wear after a certain length of cutting is used the
concept, specific tool wear (usp), defined by the equation:

u sp

1000 u
L

[m/1000m] (2)

The specific tool wear, is the tool wear measured with m, in the radial direction reported
to 1000 m length of cutting. If we take into account the rapid initial wear (ui ), the tool wear (u)
can be calculated with the formula:

u u i u us

L
1000

[m] (3)

The value of the rapid initial wear is given in the literature depending on the tool
material. To determine the specific tool wear, the cutting tool must be used, for removing the
rapid initial wear. In this case the equation is:

U uus

L
1000
L

or

uus

U 1000
L

[m/1000m] (4)

d l
1000 s

[m] (5)

where: L cutting length, [mm]; d (Dm) - machined diameter, [mm]; l (lm) machined
length,[mm]; s (fn) feed per revolution [mm/ rev].
The tool wear is influenced by cutting speed, tool material and hardness of the processed
material. The variation of the tool wear according to the cutting speed for carbide inserts is
presented in figure 6.

Fig.6. The variation of the tool wear according to the cutting speed for carbide inserts
when processing steel

This mathematical formula is credited to F. W. Taylor (~1900):

vT n C (6)

where: v = cutting speed; T = tool life; and n and C are parameters that depend on feed,
depth of cut, work material, tooling material, and the tool life criterion used n is the slope of the
plot, C is the intercept on the speed axis.
Tool failure modes identify the important properties that a tool material should possess:

Toughness - to avoid fracture failure

Hot hardness - ability to retain hardness at high temperatures

Wear resistance - hardness is the most important property to resist abrasive wear

The tool wear produces a dimensional deviation on the parts during the turning process.
Dimensional deviation due to tool wear it is:

d 2u [m] (7)
III.

Experimental work

In this paper shafts with the same size and same hardness will be processed. To analyze the
influence of the tool material on the tool wear will be used two different cutting tools: one made
by speed steel and one with carbide insert. The cutting tools will be used after the rapid initial
wear was removed.
To measure the tool wear the device shown in Figure 7 is used.

Fig. 7 The device used to measure the tool wear

1. The workpiece (shaft) is clamped on the turning lathe. The shaft diameter is measured.
2. The tool measurement device is adjusted to zero.
3. The cutter is clamped on the tool holder.
4. The process parameters (feed per revolution, cutting depth and spindle speed) are adjusted
5. The cutting process is started. It is interrupted after 1 minute, 2 and 3 minutes. After stop the
cutter is measured in two steps: first is measured tool wear and deformation and after cooling
is measured just tool wear.
6. A new workpiece is clamped onto the lathe. Steps 2-5 are repeated, using a cutter with a
carbide insert.

IV.

Processing the results

1. Table 1 will be completed with the cutting parameters, shaft dimensions and the tool wear.
2. The cutting length will be calculated using equation (5) and specific tool wear with equation
(2).
3. The diagrams for variation of tool wear depending on the cutting length for each case will be
draw (Figure 6).

Fig. 6. The variation of tool wear depending on the cutting length

Table 1.
The wokpiece

Tool tipe

Process parameters

material tipe

The workpiece
dimensions

t (ap) [mm] =

lp [mm] =

s (fn) [mm/ rot] =

d (Dm)[mm] =

n [rot /min] =
The cutting time [min]
1

l (lm) [mm]
L [mm]
U [m]
Dd [m]
usp [m/1000m]
tool wear and
deformation [m]

V.

Conclusions and observations

1. Tool wear variation depending on the cutting length will be analyzed.

2. The material hardness influence on the tool wear will be analyzed.
3. The dimensional deviation caused by the tool wear will be analyzed.