Development and implementation of crater and flank tool wear model for hard turning simulations

Abstract This paper concerns the tool wear in hard turning of AISI 52100 hardened steel by means PCBN tools. The purposes this work are development a model and its implementation FEM-based procedure for predicting crater flank progression during machining operations studying influence on process terms geometry modifications stress variation tool. developed model, able to update worn as function rate, has been implemented utilized Deform 2D FEM software. new analytical differs from already proposed methods existing research, since it both evaluation. validation achieved comparison between experimental simulated parameters. For doing this, an extended campaign accomplished. results have shown good agreement. Once validated, strategy examining effective rake angle related stresses, individuating excessive positive value final breakage mechanism.