Simulation Based Prediction of 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 allow an economic and secure design of manufacturing processes. For complex milling tasks, e.g. milling of sculptured surfaces, simulations can help to predict the dynamic behaviour of manufacturing machines, to estimate process forces and to forecast chatter. Another important aspect is the knowledge of the resulting tool wear during the cutting process, not only to produce high quality products but also to avoid any waste of tools capacity. In order to achieve useful results for a wear-predicting simulation, the system, based on an empirical model has to be parametrized with data concerning the workpiece material, cutting material and further influencing factors that remain constant during a milling process. Different variable process parameters, as the feed rate, the engagement situation, the cutting speed as well as the cut volume strongly interact and their impact on the process and the tool at different wear states has to be incorporated in an appropriate simulation model. Changes of these sets of parameters and therefor their influence on the development of tool wear can either be measured with the help of fully factorial tests or a statistical design of experiments (DoE) can be applied to reduce the experimental effort. This article describes an appropriate simulation system and the development of a model for the prediction of tool wear in milling. It also presents the use of DoE and the verification of the simulation system on the basis of measured data from real cutting processes.


Production Process, Milling, Tool Wear, Simulation, DoE


In: Proceedings of the 2nd Manufacturing Engineering Society International Conference, CISIF-MESIC 2007, 9.7.-11.7. 2007, Madrid, Spain, ISBN 978-84-611-8001-1, digital veröffentlicht