Journal article
Tailoring tool edge profile via through-life wear visualization
Journal of manufacturing processes, Vol.165, pp.133-148
05/15/2026
DOI: 10.1016/j.jmapro.2026.02.067
Abstract
As a critical functional component of a machine tool, the cutting edge undergoes severe and continuous tribological interaction with the workpiece during machining. Its geometry plays a crucial role in determining cutting performance, particularly the tool's wear resistance. However, the tool edge profile (TEP) evolves continuously in microscale during wear progression, making its experimental characterization highly challenging. This study presented a through-life wear visualization approach for TEP during milling process. A modified mechanism-based wear rate model for the tool-workpiece system was analytically derived, experimentally calibrated, and implemented through a user subroutine. TEP was iteratively updated using a Delaunay triangulation-based remeshing strategy built on the Particle Finite-element Method (PFEM). Wear simulations through an intermittent cutting model were carried out for tools prepared with rounded, trumpet-shaped, and waterfall-shaped TEPs. Results reveal that, regardless of the initial TEP, a trumpet-shaped edge with nearly identical flank segment length emerges after a short cutting duration. To describe this early-stage converging behavior, a new parameter, maximum converging distance, is introduced and analyzed with respect to tool life. The results indicate that shorter maximum converging distance generally correlate with longer tool life. Leveraging this finding, the life of a monolithic carbide tool was enhanced by up to 27% through tailored TEP preparation for shoulder milling of Inconel 718 alloy. This work provides new insights into TEP evolution during machining and offers practical guidance for designing high-performance cutting edges.
•Precise and model-friendly characterization method to curvilinear TEPs•Through-life wear visualization of various TEPs for milling process•Finding of converging phenomenon in wear progression regardless of initial TEPs•High correlation between maximum converging distance and tool life improvement•Mapping-based intuitive tool life improvement strategy for tailoring milling TEPs
Details
- Title: Subtitle
- Tailoring tool edge profile via through-life wear visualization
- Creators
- Cheng Hu - Wuhan University of TechnologyKejia Zhuang - Wuhan University of TechnologyHongtao Ding - University of Iowa
- Resource Type
- Journal article
- Publication Details
- Journal of manufacturing processes, Vol.165, pp.133-148
- DOI
- 10.1016/j.jmapro.2026.02.067
- ISSN
- 1526-6125
- eISSN
- 2212-4616
- Publisher
- Elsevier Ltd
- Number of pages
- 16
- Language
- English
- Date published
- 05/15/2026
- Academic Unit
- Mechanical Engineering
- Record Identifier
- 9985147202402771
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