Finite element (FE) technique has been used extensively to have a deeper understanding on the mechanics of metal cutting and for process optimization. The accuracy of the model is dependent on both the highly non-linear material plasticity model and the simulated friction condition between contacting surfaces. Hence, majority of the predicted results were validated from direct or indirect experimental results. Measurement of cutting forces magnitude and temperature field are direct techniques to validate the model. Indirect methods are chip morphology and residual stresses measurement from the newly generated surface. In this paper, a unique indirect method is proposed to validate the accuracy of the FE model. This method predicts the tool wear rate by using the average contact pressure and interface temperature acquired from finite element simulation, as the inputs for the Usui’s tool wear rate equation. Orthogonal cutting experiments were performed in specific ranges of cutting speed and feed rate. The workpiece material used was AISI 1045 at 86 HRB, and tool material was uncoated carbide. Tool cutting edge geometry was analyzed in different steps of the cutting process, and worn edge geometries were obtained. The worn edge geometries were then used to build the FE cutting models. Based on the simulation results when the flank wear length increases, the temperature field prediction showed that the region of maximum temperature shifted from the rake face to the flank face region. The contact pressure increased substantially with cutting speed rather than feed rate. The predicted wear rate agreed well with experimental results. Using tool wear rate to predict the accuracy of the FE cutting model is limited to the orientation of the rake and flank face surfaces.

有限元 (FE) 技术已被广泛用于深入了解金属切削力学和工艺优化。模型的准确性取决于高度非线性的材料塑性模型和接触表面之间的模拟摩擦条件。因此，大部分预测结果均通过直接或间接实验结果进行验证。切削力大小和温度场的测量是验证模型的直接技术。间接方法是从新生成的表面测量芯片形态和残余应力。在本文中，提出了一种独特的间接方法来验证有限元模型的准确性。该方法通过使用从有限元模拟获得的平均接触压力和界面温度作为臼井刀具磨损率方程的输入来预测刀具磨损率。正交切削实验是在特定的切削速度和进给率范围内进行的。使用的工件材料为 AISI 1045，HRB 为 86，刀具材料为未涂层硬质合金。在切削过程的不同步骤中分析刀具切削刃几何形状，并获得磨损边缘几何形状。然后使用磨损的边缘几何形状来构建 FE 切割模型。根据模拟结果，当后刀面磨损长度增加时，温度场预测表明，最高温度区域从前刀面转移到后刀面区域。接触压力随着切削速度而不是进给速度显着增加。预测的磨损率与实验结果非常吻合。使用刀具磨损率来预测 FE 切削模型的精度仅限于前刀面和后刀面的方向。