Chapter 1 Introduction 1.1 Metal Cutting Theory 1.2 Finite Element Simulation of Cutting Process 1.2.1 Numerical Aspects 1.2.2 Mechanical Aspects 1.3 Technical Background About Tool Wear 1.3.1 Wear Types in Metal Cutting 1.3.2 Wear Mechanism 1.3.3 Tool Wear Model 1.4 Research of Tool Wear with Finite Element Methods 1.4.1 Comparison Between FEM Method and Empirical Method 1.4.2 State of Art: Numerical Implementation of Tool Wear Estimation 1.5 Methodology of Tool Wear Estimation Based on Differential Wear Rate Model 1.5.1 Objective 1.5.2 Approach Chapter 2 Development of Differential Wear Rate Model 2.1 Introduction 2.2 Orthogonal Cutting Experiment 2.3 Determination of Wear Constants 2.3.1 Tool Wear Rate Model Relate to Flank Wear 2.3.2 Curve Fitting For Usui's Model Chapter 3 Chip Formation Simulation Technology 3.1 Introduction 3.1.1 Explicit Algorithm in Chip Formation Simulation 3.1.2 Stability Limit 3.2 Continuous Chip Formation Simulation 3.2.1 Limitation of the Existing Chip Formation Models 3.2.2 Advantages of the New-developed Chip Formation Model 3.2.3 Adaptive Meshing Technique in ABAQUS! Explicit 3.2.4 Analysis Steps 3.2.5 Results & Discussion 3.3 Chip Formation Simulation for Milling Operation 3.3.1 Chip Separation 3.3.2 Chip Formation Modeling 3.3.3 Result & Discussion 3.4 Summaries & Conclusion Chapter 4 Heat Transfer Analysis in Metal Cutting 4.1 Introduction 4.2 General Considerations 4.2.1 Geometry and Mesh 4.2.2 Heat Flux 4.3 In Turning Operation 4.3.1 Modeling 4.3.2 Results & Discussion 4.4 In Milling Operation 4.4.1 On Workpiece 4.4.2 On Tool 4.5 Summaries & Conclusion Chapter 5 Estimation of Tool Wear in Turning Operation 5.1 Introduction
5.2 Tool Wear Calculation Program Design 5.3 Modeling Procedure 5.3.1 Chip Formation and Heat Transfer Analysis 5.3.2 Wear Rate Calculation 5.3.3 Nodal Move Direction 5.3.4 Cutting Time Increment Calculation 5.3.5 Nodal Displacement 5.3.6 Tool Geometry Updating 5.4 Results & Discussion 5.4.1 Tool Wear 5.5 Summaries & Conclusion Chapter 6 Estimation of Tool Wear in Milling Operation 6.1 Introduction 6.2 Tool Wear Calculation Program Design 6.3 Modeling Procedure 6.3.1 Chip Formation Analysis 6.3.2 Heat Transfer Analysis 6.3.3 Nodal Average Wear Rate Calculation 6.3.4 Nodal Move Direction 6.3.5 Cutting Time Increment Calculation 6.3.6 Nodal Displacement Calculation 6.3.7 Tool Geometry Updating 6.4 Results & Discussion 6.5 Summaries & Conclusion Chapter 7 Summary and Prospect 7.1 Summaries 7.2 Prospect References
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