Numerical study on the ceramic tool abrasion in machining superalloy

In this study, a combined finite element method (FEM) and discrete element method (DEM) numerical simulation is proposed to investigate the tool wear evolution in machining superalloy. Firstly, a finite element model for cutting is conducted to obtain the contact stress, the temperature distribution of the cutting tool, and the speed of chip flow. Based on the boundary conditions, a discrete element model is established to display the tool-chip abrasion behavior. The micro-crack number, detached particle number, and wear rate of the ceramic tool are predicted and analyzed by discrete element simulations. Moreover, the effects of cutting speed and depth of cut on tool abrasion are numerically investigated. Subsequently, a cutting experiment is designed to compare simulated results with experimental data. The high consistency of the predicted tool wear and experiments validates that the combined FEM-DEM method is feasible to study the tool wear behavior in machining superalloy. Furthermore, process optimization guidelines are also proposed for improving machining efficiency and tool life in the actual processing. Within a certain range, higher cutting speed notably leads to slighter tool wear. The larger depth of cut causes more severe wear of Sialon ceramic tools.