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The Correlation of Volumetric Tool Wear and Wear Rate of Machining Tools With the Material Removal Rate of Titanium Alloys

[+] Author Affiliations
Mathew Kuttolamadom, Parikshit Mehta, Laine Mears, Thomas Kurfess

Clemson University, Greenville, SC

Paper No. MSEC2012-7338, pp. 387-396; 10 pages
  • ASME 2012 International Manufacturing Science and Engineering Conference collocated with the 40th North American Manufacturing Research Conference and in participation with the International Conference on Tribology Materials and Processing
  • ASME 2012 International Manufacturing Science and Engineering Conference
  • Notre Dame, Indiana, USA, June 4–8, 2012
  • Conference Sponsors: Manufacturing Engineering Division
  • ISBN: 978-0-7918-5499-0
  • Copyright © 2012 by ASME


The objective of this paper is to assess the correlation of volumetric tool wear (VTW) and wear rate of carbide tools on the material removal rate (MRR) of titanium alloys. A previously developed methodology for assessing the worn tool material volume is utilized for quantifying the VTW of carbide tools when machining Ti-6Al-4V. To capture the tool substrate response, controlled milling experiments are conducted at suitable corner points of the feed-speed design space for constant stock material removal volumes. For each case, the tool material volumes worn away, as well as the corresponding volumetric wear profile evolution in terms of a set of geometric coefficients are quantified — these are then related to the MRR. Further, the volumetric wear rate and the M-ratio (volume of stock removed to VTW), which is a measure of the cutting tool efficiency, are related to the MRR — these provide a tool-centered optimal MRR in terms of profitability. This work not only elevates tool wear from a 1-D to 3-D concept, but helps in assessing machining economics from a stock material removal efficiency perspective as well.

Copyright © 2012 by ASME



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