3D FEM simulation of tool wear in ultrasonic assisted rotary turning.

In this study, a model is developed to predict tool wear and heat distribution on tool faces in conventional, rotary, and ultrasonic assisted rotary tuning methods. To model the flank wear rate, a modified Usui wear rate model which includes tool clearance angle, is proposed. As well as the simulation, a series of experiments is conducted to validate the model, by comparison of the predicted and measured flank wear rates, which are shown to be in good agreement. According to the results of the simulation, localized heat in the tool-chip contact zone during conventional turning is distributed in the circumference of the tool cutting edge in rotary turning. Due to the existence of disengagement periods in ultrasonic-assisted rotary turning, the total time for thermal conduction in the contact zone decreases, resulting in a significant reduction in tool wear.