Effect of tool flank wear on formation and prediction of tool flank rolling angle using finite element method

The formation and determination of the tool flank rolling angle are discussed in this study. First, the relationship between the tool flank rolling angle and the distribution of the tool wear rate on the tool-flank worn zone is developed by combining the finite element (FE) method and a turning experiment, and the determination method of the tool flank rolling angle using the FE simulation is revealed. Then, the evolution of the tool flank rolling angle with the tool flank wear progress is analyzed, and the evolution of the tool flank rolling angle is also considered in the determination of constants in the Usui model for tool flank wear. Finally, the empirical model of the tool flank rolling angle based on the tool flank wear width VB is proposed based on the FE method. The empirical model results are found to be in good agreement with the experimental results. The evolution of the tool flank rolling angle is considered in tool wear prediction. Compared with the method with a constant tool flank rolling angle, the tool wear prediction accuracy of our model is improved.