Development of Mathematical Model for Tool Wear Rate Using 3-Level Response Surface Methodology

Abstract

Tool wear is the progressive loss of material from the surface of tool in the form of very small metallic particles. From decade tool wear rate was used as major criteria to predict the tool life. However, tool wear rate only measures principle wear, i.e., flank wear and face wear. In order to assesses the real damage to the tool and consider other tool wear like chip, notching, primary and secondary grooving tool wear weight was proposed as a one of the criteria to measure tool life. This project work focuses on the development of first order mathematical model to predict the tool wear rate and the validation of the result by experiment using three levels response surface methodology. Experiment was performed under dry condition. Coated carbide triangular shape tool were used for experiment and EN-8 was used as work material. Three different nose radiuses were used to perform experiment on CNC machine. Response surface method was used to study the effect of working parameter like speed, feed, depth of cut and nose radius.  The study reveals that tool wear weight was mostly affected by speed; depth of cut whereas depth of cut has negligible effect.