Wear Analysis

of Milling Cutting Tool

A DISSERTATION
Submitted in partial fulfillment of the requirement for the award of the degree of Master of
Engineering

[PRODUCTION ENGINEERING]
Submitted To

RAJIV GANDHI PRODYOGIKI VISHWAVIDYALAYA,

(University of Technology of Madhya Pradesh)
BHOPAL (M.P.)

Submitted by
Vikas Patidar
[Enrollment No.-0830AU14MT01]
Under the supervision of
Prof. SUMAN SHARMA

Department of Mechanical Engineering

TRUBA COLLEGE OF ENGINEERING AND TECHNOLOGY, INDORE
Feburary-2016

TRUBA COLLEGE OF ENGINEERING AND TECHNOLOGY,

INDORE
Department of Mechanical Engineering
CERTIFICATE

This is to certify that the work embodies in this dissertation entitled Wear
analysis of milling cutting tool being Submitted by VIKAS PATIDAR
[Enrollment No.-0830AU14MT01] in partial fulfillment of the requirement for
the award of Master of Technology in PRODUCTION ENGINEERING to
RAJIV GANDHI PRODYOGIKI VISHWAVIDYALAYA, BHOPAL (M.P.)
during the academic year 2014-2016 is a record of bona fide piece of work,
carried out by him under my supervision and guidance in the Department of
Mechanical Engineering, TRUBA COLLEGE OF ENGINEERING AND
TECHNOLOGY, INDORE

Guided By:
Prof. Suman Sharma
HOD, ME

Dr. -------------------

Dr. --------------------

Dean PG TCET, INDORE

Director TCET, INDORE

TRUBA COLLEGE OF ENGINEERING AND TECHNOLOGY,

INDORE
Department of Mechanical Engineering
DECLARATION
I Vikas Patidar a student of Master of Technology in Production
Engineering Branch, session 2014-2016, here by informed that the work
presented in this dissertation entitled Wear analysis of milling cutting tool is
the outcome of my own work, is bona fide and correct to the best of my
knowledge and this work has been carried out taking care of Engineering
Ethics. The work presented does not infringe any patented work and has not
been submitted to any other University or anywhere else for the award of any
degree or any professional diploma.

NAME- Vikas Patidar

Enrollment No. 0830AU14MT01

TRUBA COLLEGE OF ENGINEERING AND TECHNOLOGY,

INDORE
Department of Mechanical Engineering
CERTIFICATE OF APPROVAL

The dissertation entitled Wear analysis of milling cutting tool being

submitted by VIKAS PATIDAR [Enrollment No.-0830AU14MT01] has
been examined by us and is hereby approved for award of Master of
Technology in Production Engineering, for which it has been submitted. It is
understood that by this approval the undersigned do not necessary endorse or
approve any statement made, opinion expressed or conclusion drawn therein,
but approve the dissertation only for the purpose for which it has been
submitted.

(Internal Examiner)

(External Examiner)

ACKNOWLEDGEMENT
We take this opportunity to express our profound gratitude and deep regards to
our guide Professor
Prof. Suman Sharma for his exemplary guidance, monitoring and constant
encouragement throughout the First phase of this project. The blessing, help and
guidance given by time to time shall carry me a long way in the journey of life
on which we are about to embark.
We would like thank to Prof. for providing us assistance in various hardware
and software problem encountered during course of our project.
We are obliged to faculty members of the Truba College of engineering and
Technology, Indore, for the valuable information provided by them in their
respective fields. We are grateful for their cooperation during the period of our
assignment

Date:

VIKAS PATIDAR (0830AU14MT01)

Dept. of Production Engineering

CONTENTS
CERTIFICATE.04
i
ACKNOWLEDGEMENTS..........05
ii
CONTENTS06
ABSTRACT08
vii
Chapter
Introduction09
2
1.1 Current Scenarios about oblique and orthogonal cutting...09
3
Chapter 2:
Literature Review..12
5
2.1 Assisted mode12
2.2 Drill of a rotating work piece...........12
2.3 The effects of uncut chip thickness ..12
5
2.4 Chip formation study ....12
2.5 Orthogonal Cutting13
5
Chapter 3: Problem Formulation & Objective..18
3.1 Problem Identification..18
3.2 Objective18
3.3 Innovation.19
Chapter 4: Methodology...20
8
4.1 Layout of Proposed System20
4.2 Mechanism.20
Chapter 5: Present work..21
5.1 Work which is done..21
5.1.1 Initiation and Problem identification21
5.1.2 Study of literatures22
6

5.1.3 Proposed system22

5.2 Work which is so far.22
5.3 Discussion...23
24
Chapter 6: Conclusions.25
26
26
References26

Abstract
The material removal process uses cutting tools in order to produce the desired shape of the
work piece. Tool wear has been a problem for cutting tools, since cutting tools wear and
break. Research has been accomplished in the tool wear field for tool life and more recently
tool wear. The computer generation has created a method to simulate the material removal
process. These computer simulations model the cutting tool reaction with the work piece.
Many of the simulation models use finite element analysis to calculate the reaction of the
cutting tool.

Different finite element models are being used throughout the world for

research. In this project we will use Ansys 14.5 to simulate and predict the wear of the
cutting tool.
The cutting forces exerted by the cutting tool on the work piece during a machining action to
be identified in order to control the tool wear and occurrence of vibration, thus to improve
tool-life. Modeling of cutting forces in milling is often needed in machining automation. The
objective of this study is to predict the effects of cutting parameters on the variations of
cutting forces during end milling operation of 1018 series steel alloy material. The cutting
forces will be obtained by analysis in Ansys 14.5.Software.
The transient analysis will be use for a specified duration of time. The maximum stressed
area and stress values will be calculated using Ansys 14.5. Response surface methodology
will be used by designing three factors and the five levels central composite rotatable design
matrixes with full replication; for planning, conduction, execution and development of
models. The average cutting forces have been determined at defined value of the parameters
(feed, speed, depth of cut) in tangential, radial, and axial direction per tooth period. The
immersion and axial depth of cut will maintain constant. A comparison between modeling
7

and experiment also perform. This model and analysis will useful not only for predicting the
tool wear but also for selecting optimum process parameters for achieving the stability of the
end milling process.

Keywords: Finite Element Analysis, Orthogonal Cutting, FEM, Ansys

CHAPTER-1 INTRODUCTION
1.1 Current Scenarios about tool signature term
A common method to manufacture parts to a specific dimension involves the removal of
mass amounts of material by machining operations. This process involves the workpiece
or material, the machine and cutting tools. The material removal process was performed
when the machine uses the cutting tool to remove material from the workpiece. Specific
dimensions and tolerances are defined by a drawing to give the workpiece its final shape.
Metal removal machines today are controlled by computers for precise and repeatable
positioning. Turning machines have computer controls to monitor and allow changes in
all operations of the machine. Turning machines are a popular method to remove material
for cylindrical parts and some non-cylindrical parts with the newer machines that
accommodate live tooling.

The cutting tools used to remove material in a turning

machine can cut parts accurately and within tolerance for a time before they wear or
break. Tool wear and breakage has been an issue with cutting tools since they were
created. Tool wear weakens the cutting tool, increases the forces used in cutting and
causes a lack of consistency in material removal. Parts and time lost to scrap and rework
from tool wear are costly to companies. Companies spend money to grind and replace
cutting tools due to tool wear. There are many factors that contribute to the wear of
cutting tools: the workpiece properties, cutting tool properties, cutting surface speed,
cutting feedrate, depth of cut and machine rigidity.

1.2 FEA Tool

Demonstration to use concepts involving the finite elements modeling and analysis (FEA)
along with growth in the field of computer technology has to an extent reduced the need for
conducting the metal cutting experiments. A lot of researchers have applied the FEA concept
to model metal cutting simulations, not many have validated the simulated results against the
real time experiments to make the model more dependable/reliable. There are several
commercial FEA simulation softwares available in the market ANSYS, ABAQUS, LS-Dyna,
AdvantEdge to mention a few with each of them having its own advantages and
disadvantages.
In current study focuses on building a 2-Dimensional Finite element model to simulate the
wear analysis under a dry machining environment in an Academic available FEA tool
ANSYS.
In this study the transient analysis will be use for a specified duration of time. The maximum
stressed area and stress values will be calculated using Ansys 14.5. Response surface
methodology will be used by designing three factors and the five levels central composite
rotatable design matrixes with full replication; for planning, conduction, execution and
development of models. The average cutting forces have been determined at defined value of
the parameters (feed, speed, depth of cut) in tangential, radial, and axial direction per tooth
period. The immersion and axial depth of cut will maintain constant. A comparison between
modeling and experiment also perform. This model and analysis will useful not only for
9

predicting the tool wear but also for selecting optimum process parameters for achieving the
stability of the end milling process.

CHAPTER-2 LITERATURE REVIEW

2.1 Assisted mode

There are many different types of Solutions with different ways of activating the FEA,
Ansys is one of them
2.2 Background information
Background information was gathered on cutting tools, tool wear and finite element analysis
to highlight some of what has occurred in tool wear studies. Research for this thesis was
done on Archards law and computer simulation capabilities.
2.3 Cutting tools
In this thesis, background on cutting tools was done in order to understand what tool
geometry has been used before with HSS tools. HSS cutting tool geometry has been studied
to arrive at the current tool geometry. Over the past few years cutting geometry has changed
slightly for HSS tooling. In Table 2.1 the various tool geometries found in different books are
listed. Also added was the tool geometry that this thesis will use.

10

In a study by Albert J. Shih he used annealed 1020 carbon steel along with HSS cutting tools
to study the effects of the rake angle of the cutting tool. The initial finite element used
perfectly sharp cutting tools to identify what the differences and similarities of the
deformation of the work material. A later finite element used worn cutting tools to examine
residual stresses under the cut surface. The finite element mesh used ten layers to model the
chip formation, four layers for under the cut surface, and four layers for distributions of the
residual stresses. However the lengths and heights of these layers vary depending on the rake
angle used. As the cutting tool proceeds, the mesh rezoning technique is applied to add,
refine, combine, and delete columns of elements in front of
and behind the cutting tool until the steady-state chip formation is achieved(Shih 1996).
The research used finite element to understand what occurred when the rake angle changed
from -2, 0, 5, and 15. The trends that occurred in this study are shown in Table 2.2. A
conclusion reached for this research was that the deformed finite element mesh was still not
adequate for the work-material model.
2.4 Tool wear
11

Tool wear mechanisms most studies agree that there are 5 basic causes of wear. Tool wear
mechanisms are divided into 5 categories and can occur in combination with the others or
singly. The causes of wear do not always behave in the same manner, nor do they always
affect wear to the same degree under similar cutting conditions. (Nee 1998) The 5
categories are listed below with a brief explanation.
1. Abrasive wear was a mechanical action that occurs when hard particles found within the
workpiece cut, chip, groove of the cutting tool surface.
2. Plastic deformation of the cutting edge was caused by the extreme pressure imposed on
the cutting edge that causes a depression or bulging of the edge. The more the tool deforms
the greater the pressure and temperature on the tool resulting in more deformation and
possible edge wipe out.
3. A chemical reaction between the tool and the workpiece occurs at elevated temperature.
The tool has tiny sections that are weaken due to the pressure and temperature of the cutting
process. These tiny sections have smaller particles within them that react to the workpiece
material thus forming a bond between the tool and the workpiece. As the bond strengthens
the weakened particles from the tool are carried away with the chip or stay with the
workpiece.
4. Diffusion between work and tool material occurs when a section of the tool reaches a
critical temperature and a change in composition happens between the tool and the chip
interface. This composition change usually induced by elevated temperature and the bond
between the section and the chip strengthen as the section was torn away from the tool.

5. The welding of asperities between workpiece and the tool occur at lower temperatures
than the diffusion and chemical reaction. These asperities are joined to the workpiece
material as it was removed in the work-hardened chip. The high pressure in the cutting
process enables the asperities to be pulled away from the tool as the chip removed from the
workpiece.

Research has been done in tool wear in many different categories. A few of

these categories are finite element analysis, neural networks, and predictive mapping. The
majority of research in tool wear uses the finite element analysis method to predict tool wear.
Further background for finite element analysis for this thesis can be found later in this
chapter.
12

CHAPTER-3 PROBLEM FORMULATION AND OBJECTIVE

3.1 Problem Statement
We will design 2-d model of tool and work piece. And perform finite element analysis for
wear analysis of milling cutting tool. We will investigate in detail to explore the machining
The computer simulation tool wear has been a growing source for research. This study will
examine whether there was any correlation between standard tool wear and computer
simulated tool wear using an updated finite element analysis with Ansys 14.5. This study
will give computer simulated turning data to see the prediction of tool life after reduction of
tool wear. In this project we will analyze the tool wear on Ansys 14.5 FEA software for
predicting the tool life and stability according to the tools parameters like cutting force, thrust
force etc.
3.2 Objectives

The major objectives and pertinent work plan to fulfill these can be broadly summarized as:

To study the effects of different cutting parameters, tool geometry, cutting

environment

To improve cutting process.

To predict the temperature distribution.

To predict tool wear

3.3 Innovation
Innovations are done to make the Cutting process more efficient and user friendly than the
conventional. The major innovations are as follows:

From FEA solution it is possible to predict the tool wear at any given cutting time
The tool work piece interface temperature is increased with an increase in cutting speed
The cutting force at the beginning of the cutting process is large and further decreases
with subsequent incremental displacement.
13

CHAPTER-4 METHODOLOGY
4.1 Layout of Proposed System
Methodology

Comparison of results

Features:

The idea for Finite element analysis of predicting tool wear of milling tool is to provide a
improve, safer, efficient and less friction metal cutting

It may be increase the tool life.

CHAPTER-5 PRESENT WORK

1.1 Work which is done

14

15-31
Dec. 2015

01-15
Dec.2016

16-31
Dec.2016

1.1.1

Initiation and Problem identification

Study of literatures

Proposed system

Initiation and Problem identification

Tool wear has been a critical issue in metal removal processes. In turning, tool wear can
create parts that are out-of-tolerance and eventually cause tool failure. Tool wear and
breakage has been an issue with cutting tools since they were created.

Tool wear

weakens the cutting tool, increases the forces used in cutting and causes a lack of
consistency in material removal. Parts and time lost to scrap and rework from tool wear
are costly to companies. Companies spend money to grind and replace cutting tools due
to tool wear. There are many factors that contribute to the wear of
cutting tools: the workpiece properties, cutting tool properties, cutting surface speed,
cutting feedrate, depth of cut and machine rigidity.

1.1.2 Study of literatures

In a study by Albert J. Shih he used annealed 1020 carbon steel along with HSS
cutting tools to study the effects of the rake angle of the cutting tool. The initial finite
element used perfectly sharp cutting tools to identify what the differences and
similarities of the deformation of the work material. A later finite element used worn
cutting tools to examine residual stresses under the cut surface. The finite element
mesh used ten layers to model the chip formation, four layers for under the cut
surface, and four layers for distributions of the residual stresses. However the lengths
15

and heights of these layers vary depending on the rake angle used. As the cutting
tool proceeds, the mesh rezoning technique is applied to add, refine, combine, and
delete columns of elements in front of and behind the cutting tool until the steadystate chip formation is achieved(Shih 1996).
The research used finite element to understand what occurred when the rake angle changed
from -2, 0, 5, and 15. The trends that occurred in this study are shown in Table 2.2. A
conclusion reached for this research was that the deformed finite element mesh was still not
adequate for the work-material model.
TOOL WEAR
Tool wear mechanisms most studies agree that there are 5 basic causes of wear.
Tool wear mechanisms are divided into 5 categories and can occur in combination with the
others or singly. The causes of wear do not always behave in the same manner, nor do they
always affect wear to the same degree under similar cutting conditions. (Nee 1998) The 5
categories are listed below with a brief explanation.
1. Abrasive wear was a mechanical action that occurs when hard particles found within the
workpiece cut, chip, and groove of the cutting tool surface.
2. Plastic deformation of the cutting edge was caused by the extreme pressure imposed on
the cutting edge that causes a depression or bulging of the edge. The more the tool deforms
the greater the pressure and temperature on the tool resulting in more deformation and
possible edge wipe out.
3. A chemical reaction between the tool and the workpiece occurs at elevated temperature.
The tool has tiny sections that are weaken due to the pressure and temperature of the cutting
process. These tiny sections have smaller particles within them that react to the work piece
material thus forming a bond between the tool and the work piece. As the bond strengthens
the weakened particles from the tool are carried away with the chip or stay with the work
piece.
4. Diffusion between work and tool material occurs when a section of the tool reaches a
critical temperature and a change in composition happens between the tool and the chip
interface. This composition change usually induced by elevated temperature and the bond
between the section and the chip strengthen as the section was torn away from the tool.
16

5. The welding of asperities between work piece and the tool occur at lower temperatures
than the diffusion and chemical reaction. These asperities are joined to the work piece
material as it was removed in the work-hardened chip. The high pressure in the cutting
process enables the asperities to be pulled away from the tool as the chip removed from the
work piece.

Research has been done in tool wear in many different categories. A few of

these categories are finite element analysis, neural networks, and predictive mapping. The
majority of research in tool wear uses the finite element analysis method to predict tool wear.
Further background for finite element analysis for this thesis can be found later in this
chapter.

A study by J.H. Lee and S.J Lee was conducted in South Korea that used S45C as a
workpiece and uncoated carbide cutting tools. This researched used a neural network model
from a force ratio and readings from a dynamometer to predict flank wear in turning. Two
different force ratios and a force increment were incorporated into neural networks to predict
tool wear. The first force ratio was the ratio between the feed force and the tangential force,
while the second was a modification that includes the radial force. A force increment of the
tangential and the feed forces were used for learning in another neural network. This
research stated that the second force ratio was more accurate ratio because of the three forces
used. The model the neural network used to predict the tool wear was based on a multilayer perception which consists of input, hidden, and output layers and uses error-backpropagation algorithm for learning(Lee 1999). To train the neural networks 3 of the 9 tests
were used to train all three of the networks. The force increments average prediction error
was about 10.3%. When force ratio 1 was used for prediction the average error was about
11.9%. The average of the prediction errors when force ratio 2 was used was about 8.0%.
The study showed that force ratio 2 was more accurate than force ratio 1 and the force
increment in predicting flank wear. The results of the study predicted that as the cutting
distance increased the flank wear also increased.
In a predictive mapping study by X.P. Li, H.H. Ng, and S.C. Lim from the National
University of Singapore, estimated tool wear using 1050 steel as the workpiece and uncoated
tungsten carbide cutting tools. This study used the theoretical model of Kannatey-Asibu that
takes the heat generated from the tool flank-workpiece interface. Li, Ng, and Lim modify the
17

model by adding in the heat transfer from the shear zone and the tool-chip interface along
with the frictional heat from the flank-workpiece to create an accurate model of the heat
transfer phenomena. This modified model was then used to predict the rate of flank wear on
the tool. Next the wear maps are generated off of the predicted tool wear rates. This wearrate model system was explained in the study by going through a series of steps. Theses steps
are to specify variables for the wear-rate map and the steps are: specifying conditions to be
input into the simulator, running the simulator to obtain the required outputs, converting the
output data to pressures and temperature at the tool tip, calculating the wear-rate from the
pressures and temperature for the diffusion and adhesion wear parameters, gather the results
of the wear rate and generate a wear-rate map. Once the maps were generated they were
compared to experimental data that showed good agreement. This study did not base its wear
maps on the experimental data because of the lack of data points; they instead imposed the
experimental data onto the predicted wear-rate maps (Li 1999).

1.2 Work which is so far

18

01-07
March2016

Cost estimation

08-31
March2016

Designing of tool and work piece

01April-15
March2016

Starting of Simulation

5.3 Discussion

Catia V5
CATIA - which stands for computer aided three-dimensional interactive application - is
the most powerful and widely used CAD (computer aided design) software of its kind in
the world. CATIA is owned/developed by Dassault Systems of France and until 2010,
was marketed worldwide by IBM.
FEA
In general, there are three phases in any computer-aided engineering task:
Pre-processing defining the finite element model and environmental factors to be
applied to it
Analysis solver solution of finite element model Post-processing of results using
visualization tools

Pre-processing
The first step in using FEA, pre-processing, is constructing a finite element model of the
structure to be analyzed. The input of a topological description of the structure's geometric
features is required in most FEA packages. This can be in either 1D, 2D or 3D form, modeled
by line, shape, or surface representation, respectively, although nowadays 3D models are
predominantly used. The primary objective of the model is to realistically replicate the
19

important parameters and features of the real model. The simplest mechanism to achieve
modeling similarity in structural analysis is to utilize pre-existing digital blueprints, design
files, CAD models, and/or data by importing that into an FEA environment. Once the finite
element geometric model has been created, a meshing procedure is used to define and break
up the model into small elements. In general, a finite element model is defined by a mesh
network, which is made up of the geometric arrangement of elements and nodes. Nodes
represent points at which features such as displacements are calculated. FEA packages use
node numbers to serve as an identification tool in viewing solutions in structures such as
deflections. Elements are bounded by sets of nodes, and define localized mass and stiffness
properties of the model. Elements are also defined by mesh numbers, which allow references
to be made to corresponding deflections or stresses at specific model locations.

Analysis (computation of solution)

The next stage of the FEA process is analysis. The FEM conducts a series of computational
procedures involving applied forces, and the properties of the elements which produce a
model solution. Such a structural analysis allows the determination of effects such as
deformations, strains, and stresses which are caused by applied structural loads such as force,
pressure and gravity.

Post-processing (visualization)
These results can then be studied using visualization tools within the FEA environment to
view and to fully identify implications of the analysis. Numerical and graphical tools allow
the precise location of data such as stresses and deflections to be identified.
CHAPTER-6 CONCLUSION

It is possible to predict the evolution of tool wear at any given cutting time from FEA
solutions.

The cutting force at the beginning of the cutting process is large and further decreases
with subsequent incremental displacement.

REFERENCE

20

deepblue.lib.umich.edu
nptel.ac.in
www.oocities.org
https://www.youtube.com
faculty.ksu.edu.sa
Science Direct
Halil Bil, Engin Kilic, S. Erman Tekkaya, A. A comparison of orthogonal cutting data
from experiments with three different finite element models. International Journal of
Machine Tools & Manufacture.

Liu, C.R. and Guo, Y.B. Finite element analysis of the effect of sequential cuts and
tool-chip friction on residual stresses in a machined layer. International Journal of
Mechanical Sciences, 2000

Akbar, F. Mativenga, P.T. Sheikh, M.A. An experimental and coupled thermomechanical finite element study of heat partition effect in machining. International
Journal of Advanced Manufacturing Technology, 2010

Ozlu, E. Budak, E. Molinari, A. Analytical and experimental investigation of rake

contact and friction behavior in metal cutting. International Journal of Machine Tools
& Manufacture, 2009

Khalili, K. and Safaei, M. FEM analysis of edge preparation for chamfered tools.
International Journal of Material Forming, 2009

Davim, J.P. and Maranhao.C. A study of plastic strain and plastic strain rate in
machining of steel AISI1045 using FEM analysis. Materials and Design, 2009

Umbrello, D.Rizzuti, S. Outeiro, J.C.Shivpuri, R. Saoubi, M.R.Hardness-based flow

stress for numerical simulation of hard machining AISI H13 tool steel, Journal of
Materials Processing Technology,2009

Huang, Y. and Liang, S.Y. Modelling of the cutting temperature distribution under
the tool flank wear effect. Journal of Mechanical Engineering Science, 2003

Mamalis, A.G. Horvath, M. Branis, A.S. Manolakos, D.E. Finite element simulation
of chip formation in orthogonal metal cutting, Journal of Materials Processing
Technology 2001

Biermann,D. Hohne,F. Sieben,B. Zabel,A. Finite element modeling and Three

dimensional simulation of the turning process incorporating the material hardness.
International Journal of Material Forming, 2010

21

22