Criterion to evaluate diffusive wear in 3D simulations when turning AISI 1045 steel

This paper deals with the simulation of cutting processes. In particular, 3D FE simulations were carried out in order to estimate tool wear development during turning operations. An analytical model taking into account diffusive wear mechanism has been implemented in a proper software subroutine for the tool wear evaluation. Preliminarily conducted experimental tests allowed the analytical expression coefficients evaluation. The adopted wear model gave the possibility of correctly defining the tool wear during both the (initial) transient phase and the steady-state of the analyzed turning operation. A comparison between experimental and simulative results showed a general good agreement. The final goal of the research is to identify a FE based strategy to be reliably used to forecast tool geometry and cutting parameters influences on tool wear.