Crack propagation and wear estimation of ceramic tool in cutting inconel 718 based on discrete element method

The crack propagation and wear evolution of Sialon ceramic tool in cutting Ni-based super-alloy Inconel 718 was researched by the discrete element method(DEM) simulation and experiments. The periodic boundary and three body abrasion methods were introduced, and then a thermal-mechanical coupled model was established to describe the tool-chip tribology behavior. The isolated particles and broken parallel bonds were adopted to evaluate the crack of ceramic tool, and the length and height of spalling were used to estimate the degree of wear. Subsequently, experiments were designed by parameters. The results showed that the DEM model valid reveal the crack propagation process. In addition, process optimization was put forward to ensure comprehensive efficiency in the actual machining course. •Crack propagation and wear evolution of ceramic tools was researched by DEM.•The periodic boundary and thermal-mechanical coupling were introduced.•The isolated particles and broken parallel bonds were used to evaluated the wear.•Cutting experiments were carried out to link the DEM simulation.•Length and height were utilized to quantified the degree of wear.