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Simulation multi-étapes de l’usure des outils de coupe revêtus par une modélisation XFEM/Level-set

Abstract : In high speed machining, wear resistance of the cutting tools is improved by depositing single or multilayered coatings on their surface. However, the thermomechanical loading generated at the tool-workpiece interface greatly affects the contact zones. For this purpose, several wear modes such as cracking, abrasion, adhesion and delamination of the coating can be occurred. The study of the coatings behavior and their different degradation modes lead to better understanding of their impact on the tool life and machining process under optimal conditions. In this PhD thesis work, a multi-step numerical approach has been proposed to predict wear of the coated cutting tools. This approach involves three main steps. The first is to perform a finite element simulation of the orthogonal cutting for a short time (until the loading stabilization at the tool/workpiece interface). The second step is to recover this loading and use it as an input for the XFEM/Level-set model. The latter allow to take into account the coating layers presence without any need of mesh conforming to the interfaces. As a result, the mesh distortion is avoided when the worn tool profile is updated, as well as the CPU calculation time is drastically reduced. The final step of this approach is to convert the wear rate equation into a nodal displacement, thus representing the cutting tool wear. Based on the experimental tests, a procedure for identifying tool/workpiece contact parameters, and for calibrating the wear equation for each coating layer has been proposed. Experimental trials have been also used to validate the proposed approach
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Submitted on : Tuesday, October 2, 2018 - 12:09:07 PM
Last modification on : Friday, July 17, 2020 - 2:58:15 PM
Long-term archiving on: : Thursday, January 3, 2019 - 1:59:13 PM


Version validated by the jury (STAR)


  • HAL Id : tel-01885786, version 1


Issam Bencheikh. Simulation multi-étapes de l’usure des outils de coupe revêtus par une modélisation XFEM/Level-set. Mécanique des matériaux [physics.class-ph]. Université de Lorraine, 2018. Français. ⟨NNT : 2018LORR0094⟩. ⟨tel-01885786⟩



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