Tool life prediction in end milling using a combination of machining simulation and tool wear progress data

This study aims to establish a simple method for determining tool replacement timing based on tool wear progress. First, the relationship between machining conditions and tool wear progress was investigated via dry cutting experiments conducted using a 8.0dia. cobalt high-speed steel square end mill as the tool and a piece of SS400 steel as the work material under different spindle speeds, feed rates, and radial depths of cut. From the obtained results, a linear relationship was found between the cutting edge/workpiece contact length, and the flank wear width regardless of different cutting conditions. In this paper, a simple method for determining tool replacement timing based on this relationship and tool wear progress information is proposed. In this method tool replacement timing is determined based on correlations between the cutting edge/workpiece contact length as calculated by a machining simulation and the tool wear progress measured during machining operations. Since the correlation is determined during actual machining operations, tool wear prediction and tool replacement timing determinations are performed simultaneously, which means prior experiments are not necessary. In order to verify the validity of our proposed method, cutting experiments were conducted based on the premise of customized production, in which the machining conditions vary from one product to another. From these results, it was confirmed that the tool can be used up to its tool life based on tool wear predictions and tool replacement timing determinations.