Modelling Tool Wear in Milling

Zabel, A.1, a; Rautenberg, J.1, b

Institut für Spanende Fertigung, Universität Dortmund, Baroper Str. 301, 44227 Dortmund

a); b)


Modern process simulation tools offer the choice for an economic and secure design of manufacturing processes. They allow the prediction of the dynamic behaviour of manufacturing machines, the calculation of estimated process forces and chattering as well as the tool wear in complex milling tasks like the manufacturing of sculptured surfaces. In order to achieve useful results, the simulation systems have to be parametrized with data concerning the workpiece material, cutting material and other influencing factors which remain constant during a milling process. In order to keep the experimental effort for the calculation of these parameters as low as possible, it is necessary to apply the method known as statistical design of experiments (DoE). Furthermore different variable process parameters, as e. g. the engagement situation, the cutting speed as well as the depth and width of cut strongly interact. This results in quite different tool wear developments after the influencing factors were changed. For this reason the parameter’s impact on the process at different wear states have to be incorporated in an appropriate model for tool wear in milling. The article describes an adequate simulation system and the development of an empirical model for estimating tool wear by using DoE and measured data from real processes.


Production Process, Milling, Milling Simulation, Tool Wear


In: Manufacturing Technology, 2006, Pilsen, Czech Republik