Prediction of Remaining Useful Life of an End Mill Using ANSYS

Remaining useful life (RUL) is the amount of time remaining for a mechanical component to perform its functional capabilities before failure. There are several prognostics prediction methodologies and techniques available to determine the RUL of mechanical components. In this paper, we are applying a combination of analytical and model-based approaches to generate a tool life prediction equation for a two-flute end mill. We performed static and dynamic analysis on a two-flute end mill in ANSYS Workbench with and without crack. With the tool life results that are obtained from fatigue loading for an end mill with crack, we generated design of experiments by various techniques like Central Composite Design, Optimal Space Filling Design, Box-Behnken Design, Sparse Grid Initialization, and Latin Hypercube Design. We modeled tool life equation for the experimental data using regression techniques.