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Tool life estimation model based on simulated flank wear during high speed hard
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European Journal of Scientific Research
ISSN 1450-216X Vol.39 No.2 (2010), pp.265-278
© EuroJournals Publishing, Inc. 2010
http://www.eurojournals.com/ejsr.htm

Tool Life Estimation Model Based on Simulated Flank

Wear during High Speed Hard Turning

Erry Yulian T. Adesta

Department of Manufacturing and Materials Engineering, Faculty of Engineering
International Islamic University Malaysia, Jalan Gombak, Kuala Lumpur 53100 Malaysia
E-mail: eadesta@iiu.edu.my
Tel.: +60361964452; Fax: +60361964477

Muataz Al Hazza
Department of Manufacturing and Materials Engineering, Faculty of Engineering
International Islamic University Malaysia, Jalan Gombak, Kuala Lumpur 53100 Malaysia

Muhammad Riza
Department of Manufacturing and Materials Engineering, Faculty of Engineering
International Islamic University Malaysia, Jalan Gombak, Kuala Lumpur 53100 Malaysia

Delvis Agusman
Department of Mechanical Engineering, Faculty of Engineering
Universitas Tarumanagara, Jalan Let. Jend. S. Parman no. 1 Jakarta, Indonesia 11440

Rosehan
Department of Mechanical Engineering, Faculty of Engineering
Universitas Tarumanagara, Jalan Let. Jend. S. Parman no. 1 Jakarta, Indonesia 11440

Abstract

The aim of this research is to develop a new model for estimating tool life during
high speed hard turning based on the relationship between the flank wear progress and
time. During high speed hard turning the dominating basic wears in the flank land are
abrasive, adhesive, and diffusive. For that reasons the estimation of tool life should be
based on these three basic wears. A direct estimation method was used for modeling the
flank wear based on the volume loss due to abrasive, adhesive and diffusive wears in
turning hard materials with higher cutting speed by using ceramic cutting tool. A Matlab
simulink model was developed to simulate the tool life based on the flank wear rate.

Keywords: High speed, hard turning, flank wear, tool life, volume loss.
Tool Life Estimation Model Based on Simulated Flank Wear during High Speed Hard Turning 266

Symbols

kabrs = abrasive wear constant. kadhs = adhesive wear constant.

kdiff = diffusive wear constant.
Javg = Average flux rate
Pt = hardness of abrasive tool.
NVB=Normal load
rw = rate of wear increase
T = temperature C
o VB = length of flank wear.
ΔVB = increment of the flank wear
Vc = Cutting speed
ΔVadh =loss of volume due to adhesive
ΔVdiff =loss of volume due to diffusive
Ø = the roughness angle
L = load between surfaces
α = is the rake/chamfer angle
D = diffusion constant for the material that
is diffusing in the specific solvent.
Kabr, Kadh, Kdiff, a and Po are constants
k p =a probability constant
Pa = hardness of abrasive particle
Po = probable size of is wear particle
n w = welded joints per unit area
R = is the tool nose radius.
Δt = cutting time
Δx = The relative sliding distance
ΔVabr= loss of volume due to abrasive
x is the distance slid
j = flux
p is the hardness of the worn surface
γ = is the clearance angle
n, k = known function of the ratio between tool hardness and material
hardness.

1. Introduction
The famous formula and its extensions for estimating the tool life has been established around one
hundred years ago by Taylor and it is still used until now. Cutting tools can be used only if the surface
quality and the tolerances fall within the range of acceptance level, therefore when a cutting tool
reaches its life then it must be replaced before the cutting edge of the tool cannot produce the required
surface roughness and the accepted tolerance.
Tool life has been defined as the length of cutting time that the tool can be used (Onwubolu,
2006). Another definition for the tool life is the usable time that has elapsed before the criterion value
of flank wear is reached (Bouzid, 2005; Bouzid et al., 2005).
According to Ozel & Nadgir (2002) the prediction and detection of tool wear before the tool
causes any damage on the machined surface is very significance. This is to avoid loss of products,
damage to the machine tools, and loss in productivity. For most researchers and tool manufacturers,
tool wear progress and tool wear profile are also of utmost importance. The capability of predicting the
contributions of various wear mechanism is very helpful for the design of cutting tool materials (Gupta,
2005).
The prediction of tool wear is performed by calculating tool life through experimental work
using empirical tool life equations such as Taylor’s equation as well as its extension versions. Although
Taylor’s equation gives a simple relationship between tool life and a certain cutting parameters, as well
as its easiness to use, it is limited only to the information about tool life. In addition to that, Taylor
equations also consume a lot of money and time (Mehrban et al., 2007) since it gives relatively reliable
results only in a narrow cutting speed range (Mamalis, 2002).
During high speed hard turning the temperature in both work material and cutting tool increases
substantially due to a severe cutting condition. For that reason the estimation of tool life for the high
speed hard turning should also be seen from different aspects. Tool life has to be estimated according
to the wear rate progress on the cutting tool and the surface roughness of the work piece. These two
elements are affected directly or indirectly by cutting forces and cutting temperatures which are the
results of machining (i.e. feed rate, depth of cut, cutting speed, cutting tool material and geometry, and
work piece material).
267 Erry Yulian T. Adesta, Muataz Al Hazza, Muhammad Riza, Delvis Agusman and Rosehan

2. Research Methodology
One of the main objectives of creating tool wear model is to describe on how tool wear progress. It is
also to create a clear understanding about how different cutting parameters affect the wear process then
ultimately affect the tool life. Therefore in this research the modeling the flank wear will be carried out
through the following steps:
1. Defining the dominating wears in High Speed Hard Turning (HSHT).
2. Establishing the flank wear estimation method.
3. Mounting logical relationship model.
4. Developing a mathematical model.
5. Performing the simulation.
Fig. 1 shows the research methodology.

Figure 1: Research methodology

Theoretical study of
HSHT

Theoretical study of
wear mechanisms

No
Wear types Wear
selection
yes
No
Method
Selection
yes

Measured Machining
parameters Mathematical model parameters

Tool life estimation Input data

model

simulation Matlab simulink

End

3. Developing Wear Model for High Speed Hard Turning

3.1. Defining the dominating wears in HSHT
Under high temperature, high pressure, high sliding velocity and mechanical or thermal shock in
cutting area, the cutting tool has normally complex wear behaviors. This consists of some basic wear
types such as crater wear, flank wear, thermal crack, brittle crack, fatigue crack, insert breakage, plastic
deformation and build-up edge (Gupta, 2005; Olortegui & Kwon, 2007). Among these different types
of wear, the wear that occurs on the flank land is usually used to determine the tool life. Flank wear
directly influences the size and quality of the surface and can affect fatigue endurance limit by
affecting surface finish due to changing in the distribution of heights and slopes of the surface
(Nwokah & Hurmuzlu, 2002).
Basically, six wear mechanisms or any combinations of them are involved in the wear of
cutting tools (Carmen & Dumitru, 2008). They are abrasion, adhesion, attrition, fatigue,
dissolution/diffusion, and chemical wear. Among them the abrasive, adhesive, and diffusion are the
primary wears in the high speed hard turning process (Fig 2).
Tool Life Estimation Model Based on Simulated Flank Wear during High Speed Hard Turning 268
Figure 2: Different wears mechanisms in HSHT

HSHT

High High High sliding Mechanical Thermal

temperature pressure velocity shock shock

Complex wear behaviors

flank Crater Thermal brittle Fatigue insert Plastic

BUE
wear wear crack crack crack breakage deformation

3.2. Establishing the flank Wear Estimation Method

Having defined the flank wear as a reference for estimating the tool life then flank wear progress can
be estimated through different methods, i.e. direct or indirect methods. Fig 3 illustrates the estimating
methods that can be used in estimating flank wear progress.

Figure 3: Flank wear estimation methods

Flank Wear
estimation

Direct Indirect

Observing
Volume loss
the worn measuring
methods
Tool

Monitoring
Mathematical Surface Cutting
by Temperature Vibration
calculation roughness forces
microscope

In this research the flank wear rate will be estimated based on the volume loss method due to
the abrasive, adhesive and diffusive wear. It appears that flank wear rate in high speed hard turning
depends on following parameters;
• Tool material hardness
• Work piece hardness.
• Tool geometry: rake angle, nose radius,etc,
• Cutting condition: feed rate, depth of cut, cutting velocity
Figure 4 illustrates the relationship between the different affecting factors that will give the
basic relations to develop a direct estimation method for the tool life.
269 Erry Yulian T. Adesta, Muataz Al Hazza, Muhammad Riza, Delvis Agusman and Rosehan
Figure 4: the effect of different parameters on the tool life

3.3. Developing the Mathematical Model

Based on the previous step, the mathematical model is created in two steps;
12. Derive a function of volume change in time.
13. Derive a geometric volume change on the insert.

3.3.1. Volume change in time

The total volume of tool material removed is the summation of the three wear models; abrasive,
adhesive and diffusive. This may be expressed as follows:
ΔVTotalwear =ΔVabras +ΔVadhs +ΔVdiff (1)

3.3.1.1. Abrasive wear

Abrasion is characterized by development of grooves and ridges in the direction of tool sliding against
a newly machined surface of the work piece. With the change of cutting conditions, the tool’s
mechanical and thermal load changes, and the ratio of the wear components modifies (Mamalis et al.,
2002). The relative sliding distance Δx between tool and work piece surface in time Δt when the tool is
moving with velocity Vc is;
Δx = Vc Δt (2)
Depending on the morphology of the abrasive phases, both two and three body abrasion are
possible. The abrasive phase with complex morphologies results in 2-body abrasion while the abrasive
with simple morphologies results in 3-body abrasion. The 2-body abrasion model (Rabinowicz, 1977)
can be stated;
V2− BODY = xL tan φ π Pt (3)
An empirical, quantitative model for 3-body abrasion which brings out parameter dependencies
have been presented (Rabinowicz, 1995) as;
(
V3− BODY = KxL tan φ Pan −1 Pt n ) (4)
Where n, k is a known function of Pt Pa or Rh is defined as follow;
n=1, K=0.333 for Rh ≤ 0.8 ; n=3.5, k = 0.189 for1.25 ≥ Rh ≥ 0.8 , and n = 7, k=0.416 other wise
(Kramer, 1986).
The hardness of tool and work piece as a function of temperature can be represented using an
exponential form;
P(T ) = PO e − aT (5)
Where P (T ) is N / mm 2 , T is in C o , a and Po are constants
−3
Pa ( Fe C ) = 11760e−1.347*10 For 400>T>0; Pa ( Fe C ) = 32536e−1.3891*10 For 1400>T>401
−3

3 3

In case using the ceramic tools (TiC);

Pt ( alu min a ) = 24186e −1.616*10 For 500>T>0: Pt ( alu min a ) = 32056e−2.18*10 For 1200>T>501
−3 −3
Tool Life Estimation Model Based on Simulated Flank Wear during High Speed Hard Turning 270

In this research the ceramic was used as a material cutting tool for the following reasons
(Davim and Paulo 2008; Childs 2008):
1. High-temperature resistance enables them to be used at high cutting speeds Up to 1300–
1500ºC.
2. The prime benefit of ceramics is high hardness and thus abrasive wear and corrosion
resistance.
3. Chemical stability: in practical terms this means that the ceramic does not react with the
aterial it is cutting, i.e., there is reduction of diffusion wear.
4. For finishing cuts the ceramic insert has less than half the flank wear of CBN after 30
minutes cutting time and ceramics are ten times cheaper than CBN
The following assumption considered;
• Uniform stress distribution
• Clearance angle is zero along the contact areas.
• The condition between the flank land and the work piece as illustrated in figure 5.

Figure 5: Work piece - tool interaction (Huang & Liang 2004)

According to Fig 5 and the above assumptions, the total normal load can be expressed as the
following;
−
NVB = σ (VB ) w (6)
When the flank face with wear length VB sliding along the work piece at a velocity Vc and the
probability of generating the free abrasive particle is the same every wear on the wear land when the
tool slides, the average sliding distance for every particles is VB/2. And assuming uniform temperature
distribution along the interface; the equation for wear volume loss during the time interval Δt due to
abrasive will be (Huang & Liang 2004);
−
( )
V abrs = k abrs k Pan −1 Pt n Vc wVB σ Δ t (7)

3.3.1.2. Adhesive Wear

When two surfaces are in contact pressure and temperature micro weld formation takes place at the
interface of tool and work piece. The subsequent sliding causes shearing which can take place at the
interface and enhances adhesive wear, by assuming the micro welds as cylindrical in shape with cross
section area. After much experimentation, the laws of adhesive wear were outlined by Rabinowicz
(1995):
• Wear is directly proportional to the load between interacting surfaces
• Wear is proportional to the distance slid
• Wear is inversely proportional to the hardness being worn away.
The most up-to-date quantitative law for adhesive wear (Rabinowicz, 1995) is the modified
Holm-Archard law given by (Olortegui & Kwon, 2007)
V = k p Lx P (8)
271 Erry Yulian T. Adesta, Muataz Al Hazza, Muhammad Riza, Delvis Agusman and Rosehan

Where V is the volume of wear per sliding distance, k p is a probability constant, L is the load
between surfaces, x is the distance slid and p is the hardness of the worn surface. The probability
constant denotes one-third of the probability of generating wear debris by the adhesion mechanism.
V = k p Lx 3P (9)
Vadh = Po nwVw (10)
Where Po the probable size of is wear particle, n w is the number of welded joints per unit area.
The volume of each micro weld Vw can be
Vw = Aw hw (11)
The material removed is inversely proportional to the hardness of the material
hw ∝ 1 Pt (12)
The actual contact area is the measure of hardness of softer material, so the total tool wear in
time is given by;
−
k adh e atV c w σ Δ t (13)

3.3.1.3. Diffusive Wear

To model diffusive wear in metal cutting, the following assumption must be taken:
• Uniform temperature distribution existing along the tool-work piece interface
• The concentration of the diffusing species at the tool-work piece interface Co is treated as
constant.
• Only diffusion into the work piece and transport with the work piece are considered.
• And the dynamic nature of the system is such that the concentration gradient dc / dyavg . at any
point along the interface does not change with time. The average concentration gradient along
the tool-work piece interface can be described as;
dc dyavg = −2Co Vc D π VB (14)
Based on Fick's first law relates the diffusive flux to the concentration field, by postulating that
the flux goes from regions of high concentration to regions of low concentration, the average flux rate
is given by
J avg = − D dc dyavg (15)
Where j is the flux, D is the diffusion constant for the material that is diffusing in the specific
solvent, and dc / dyavg is the concentration gradient. The negative sign indicates that the impurities are

flowing in the direction of lower concentration.

J avg = D dc dyavg = 2Co Vc D π VB (16)
And the total wear in time Δt due to diffusion can be written as
dVdiff = Vdiff Δt (17)
dVdiff = 2Co m p Vc D π VBVBbΔt (18)
With the coefficient of diffusion D described as an exponential function of temperature
(Kannatey 1985) K diff = 2Co m( D / π ) / P being the diffusive wear coefficient, the diffusive wear loss
can be rewritten as:
− kQ (T + 273)
kdif VcVBe wΔt (19)
Tool Life Estimation Model Based on Simulated Flank Wear during High Speed Hard Turning 272

3.3.2. Geometric Definition

The previous equations gives the volume wear rate on an insert and to be able to describe the growth of
the flank wear one need to define a geometric expression of the volume worn away on every increment
of flank wear (VB). For the simplicity, the tool chosen to be analyzed here is a simple triangular
turning insert with flat chip and relief surface. To geometrically decide dv, a cross section of the insert
is made with the definitions in Fig 6 as follows (Wassdahl, J. 2008).

Figure 6: Volume losses for an insert that gain the flank wear dVB (Wassdahl, J. 2008).

dVB = dVB2 − dVB1 (20)

dv = wds (VB + dVB 2) (21)
ds = dVB(tanα /1 − tan α tan γ ) (22)
dv = wVBdVB ( tan α 1 − tan α tan γ ) (23)
The geometrical of tool material removed in time Δt will be as the following (Huang & Liang
2004; Wang et al., 2008);
dVB (cotα +tanγ)R
=
dt (VB(R−VBtanα))
( (
kabrk Pan−1 Ptn VVB )
c σ +kadhe Vcσ +kdif VVBe
at
c
−kQ(T+273)
) (24)

Where k abras , k adhs , k diff , a , k Q need to be calibrating experimentally for different tool/work
piece combinations.

4. Tool Life Estimating

To estimate the tool life from the model the following steps should be;
The wear rate is increased with the time, and then the tool life will be
Δ V B = rw Δ t (25)
L = VB rw (26)
As a result the tool life can be estimated from the following formula;
(cot α + tan γ )R
L = VB
(VB(R −VB tan α ))
( ( ) − k (T + 273)
kabr k Pan−1 Pt n VcVBσ + kadheatVcσ + kdif VcVBe Q ) (27)

This final equation is simulated by using the matlab simulink Fig 7 shows the model.
273 Erry Yulian T. Adesta, Muataz Al Hazza, Muhammad Riza, Delvis Agusman and Rosehan
Figure 7: Matlab model

5. Case Study
A model was developed using the Matlab simulink to simulate the flank wear rates by increasing the
cutting speed during cutting process of hard materials. There is no special box that can be used in the
Matlab software; therefore a new model was developed by the researchers using the Matlab simulink
as shown in Fig 7. The subsystems 1, 2 and 3 calculated the volume loss as a result of abrasive,
adhesive and diffusive wear respectively and the detailed are in appendix 1, and then the simulation
continues to estimate the tool life for different cutting speed. In order to test and running the simulating
for the final equation for estimating the tool life and comparing that with Taylor extension equation,
the researchers selected a hardened AISI 52100 bearing steel with a hardness of Rc 62 as a work piece
based on its widespread use and industrial significance and the availability of detailed data for this
material in previous works for different researchers.(Huang & Liang 2004; Huang & Liang 2007;
Poulachon et al., 2001 Poulachon et al., 2004; Huang et al., 2007; Sahin Y., 2009).
The simulation results for the wear progress for the three different types are shown in fig 8. Fig
9 shows the different behavior of tool life by using two different equations: Taylor extension and
volume loss method.
Tool Life Estimation Model Based on Simulated Flank Wear during High Speed Hard Turning 274
Figure 8: Cutting speed and wear rate due to (a) abrasive (b) adhesive (c) diffusive

Figure 9: Different estimating for tool life using the (a) Volume loss method (b) Taylor extension equation
275 Erry Yulian T. Adesta, Muataz Al Hazza, Muhammad Riza, Delvis Agusman and Rosehan

6. Analysis and Discussion

The abrasive, adhesive and diffusive volume rate increase continuously with the increasing of the
cutting speed. From the Fig 8 we can observe that:
1. All types of wear rate (abrasive, adhesive and diffusive) are increasing with the cutting speed.
a. Equation (7) it is clear that there is a proportional relation between the cutting speed and the
volume loss. The increasing in the cutting velocity will cause increasing in the volume loss due
to the abrasive wear.
b. The volume loss due to the adhesive wear increasing with increasing of the cutting speed
because of the increasing in the contact area with the time as illustrated in equation (8) then in
equation (13).
c. During high velocity and hardness the temperature will increase in the contact area between the
cutting tool and the work piece, so the diffusive wear will increase then the volume loss will
increase. This relation is illustrated in equation (18)
2. The slope of diffusion increasing starts in high level then becomes lower with the increasing of
cutting speed. These phenomena may be due to the increasing of the cutting speed, so the chip
speed will increase. According to Sharma (2001) at these speeds, heat goes out with the chip and
not into the tool or the work piece, so the wear due diffusive will.
3. The abrasive and the adhesive wear rate behave in different way, starts in lower slope then increase
with the increasing of the cutting speed.
4. The total wear is increasing rapidly with the increasing of the cutting speed.
5. The results shows that the most affect on the total wear rate are the abrasive action because both the
higher cutting speed and the hardness of the work piece have a direct effect on the abrasive wear so
the volume loss due to that will increase.
6. From Fig 9 tool life estimation by using the volume loss method the life of the cutting tool is more
suitable and realistic equation to estimate and determine the tool life

7. Conclusions
As a conclusion, the high temperature in the cutting zones makes the wear increasing in high degree in
all types of the wear mechanism. By using the volume loss method in estimating the tool life the result
becomes more accurate because of:
• Integrating all different factors in one model.
• Taking the wear rate as a reference for estimating the tool life.
• Reflecting wear rate for whole processing parameters (cutting speed, feed rate, depth of cut,
work piece hardness, and cutting tool hardness).
• Surface integrity is considered.
• The cutting tool hardness is considered.
At higher speed, higher heat is generated but each mechanism has different behavior;
o The abrasive wear increases due to high temperature while the hardness of the cutting tool
is reduced due to increasing of temperature in the cutting zone. As a consequence it will
reduce the abrasive resistance and that will also reduce the ratio between the tool hardness
and the work piece, then increasing the abrasive wear.
o The adhesive wear is increasing because in high temperature the micro welded point
increases so during the cutting the adhesive wear will also increase.
o The diffusion between the cutting tool and the work piece increase proportional with the
increasing in the temperature.
Tool Life Estimation Model Based on Simulated Flank Wear during High Speed Hard Turning 276

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Appendix 1
The appendix contains the subsystems of the matlab model that are used in the simulation.

Sub system 1: which shows the volume loss during the abrasive wear
Tool Life Estimation Model Based on Simulated Flank Wear during High Speed Hard Turning 278
Sub system 2: which shows the volume loss during the adhesive wear

Sub system 3: which shows the volume loss during the diffusive wear

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