Development of a Wear Rate Model for Uncoated Cutting Tools Based on Cutting Speed and Feed Rate Effects in Steel Machining
Authors: Siham Kerrouz, Leila Zouambi, Mokhtar Bourdim
DOI: 10.37326/ajsev8.10/2056
Page No: 77-94
Abstract
Tool wear remains a critical challenge in machining operations, particularly for difficult-tomachine materials and high-value-added components. This phenomenon results from severe thermomechanical loading at the tool-chip and tool-workpiece interfaces, where extreme conditions including large plastic deformations, high strain rates, and elevated temperatures occur during turning, milling, and drilling operations. This study presents a predictive wear model for uncoated carbide cutting tools based on fundamental understanding of physical and tribological mechanisms at contact interfaces. The proposed approach enables quantitative estimation of tool wear progression and service life prediction. Building upon established machining theories, the modeling framework addresses both flank wear and crater wear mechanisms on the rake face. The model incorporates mechanical loading conditions and contact geometry (plane-to-plane contacts) within a two-dimensional orthogonal cutting configuration. Experimental validation was conducted through systematic machining tests of 42CrMo4 steel under varying cutting speeds (1.67–5 m/s) and feed rates (0.04–0.4 mm). Results demonstrate that cutting speed is the dominant parameter influencing wear rate, with crater formation governed by diffusion mechanisms at high speeds (V > 3 m/s) and abrasion mechanisms at lower speeds. The developed model successfully predicts wear evolution and provides a reliable tool for optimizing cutting conditions and extending tool life in industrial applications.
