Developments in wear maps as machining optimisation tools
The original publication is available at http://www.isem.org.za/index.php/isem/isem2011
Conference of the ISEM 2011 Proceedings, Stellenbosch, South Africa, 21 - 23 September 2011.
Conference theme - Innovative Systems Thinking: Unravelling Complexity for Successful Solutions
Tool wear maps can be a diagnostic instrument for failure analysis. This paper presents a summary of the recent developments of wear maps and experimental results from the milling of a Ti6Al4V benchmark component. This forms the foundation of understanding the cutting demands on the tools, in order to analyze the main wear mechanisms. Remedial actions are integrated via this understanding of the failure modes and related mechanisms. These maps present wear data in a graphical manner and are able to provide a more global picture of how materials behave during cutting. In tool wear maps there is a region where the rate of wear is at its lowest, called the safe zone. The presence of this safe zone suggests that it may be possible to select the machining parameters so that a machinist can operate with the lowest amount of tool wear, without compromising the level of productivity desired. Some thoughts on future directions for research in this area are also discussed.