ANALYTICAL MODELING OF THE EFFECT OF THE TOOL FLANK WEAR WIDTH ON THE RESIDUAL STRESS DISTRIBUTION

Tool flank wear has significant effects on the cutting process, as it affects cutting forces, temperature and residual stresses. In this article, analytical models are developed to predict the cutting temperature and residual stresses in the orthogonal machining of a worn tool. In these models, measured forces, cutting conditions, tool geometry, and material properties are used as inputs. Stresses resulting from thermal stresses, fresh tool stresses and stresses due to tool flank wear are used in this analytical elasto-plastic model, and the residual stresses are determined by a relaxation procedure. The analytical model is verified experimentally with X-ray diffraction measurements. With the analytical model presented here, accurate residual stress profiles in worn tools are shown, while the computational time is significantly reduced from days, typical for finite-element method (FEM) models, to seconds.