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MOdélisation et Simulation de l’Usure des Outils de Coupe au cours du processus d'enlèvement de matière : Approche expérimentale et numérique (MOSUOC)

Abstract : The quality of finished products is one of the most important concerns of manufacturers. In fact, surface integrity is strongly related to several machining parameters such as cutting conditions, environment and especially tool wear evolution. The latest has been the subject of many researches during last decades but the majority of them were based on experimental tests and still valid for restricted cutting conditions. The lack of efficient models to simulate tool wear is explained by the fact that it is a complicated phenomenon to deal with due to different origins it can result from (abrasion, diffusion, adhesion…). In this context, the main purpose of the proposed research work is to develop a Finite Element Model based on the commercial code ABAQUS© to simulate wear phenomenon of an uncoated tungsten carbide tool insert. The study focuses on the case of orthogonal cutting operation of AISI 4140 and studies the impacts of tool wear on final functional surface integrity. The developed cutting model is based on a lagrangian description of the mesh movement. A damageable zone in the workpiece is considered to simulate the chip formation. Since tool wear occurs after several minutes, a procedure to increase the machining time simulated, named “VErtical Modeling of CUTting” (VEMCUT), is developed. The wear occurred on tool insert is taken into account by the implementation of the Archard law in Abaqus. Wear depth values are computed on each node of tool surface then a procedure for tool nodes relocation is applied. Wear coefficient needed for calculation is determined via non-lubricated experimental wear tests.
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Mayssa Guediche. MOdélisation et Simulation de l’Usure des Outils de Coupe au cours du processus d'enlèvement de matière : Approche expérimentale et numérique (MOSUOC). Autre. Université de Lyon, 2017. Français. ⟨NNT : 2017LYSEE006⟩. ⟨tel-02493414⟩

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