Search for optimum range of cutting conditions based on modeling of the cutting tool wear

This article addresses the issue of the effectiveness of using manufacturers' cutting data calculators. The methods utilized in them are analyzed. An experiment is presented that demonstrates the opposite effect, namely, obtaining a cutting process with an unsatisfactory surface quality and increased wear of the cutting tool when using an instrumental calculator. The processes affecting the wear of the cutting tool are considered. Their main types are distinguished for the purpose of zones construction in which one or another type will prevail. A method of searching for the optimal area of cutting conditions in the form of a wear map is proposed. It describes its flexible application with its parameters’ settings, such as limiting the capabilities of the equipment and the introduction of correction zones, which are necessary for accounting for the errors in the properties of the material being processed. An algorithm for its operation while using an abrasive, adhesive and diffusion mathematical model of cutting tool wear is also given. A comparative analysis was carried out, in which the tool calculator of the cutting tool manufacturer and the method for finding the optimal area of cutting conditions in the form of a map were used. Sources for filling the base are given, which are applied to assume the tool wear map functioning.

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