Wear modeling of cutting tools during orthogonal machining of unidirectional CFRP

This thesis is focused on modeling the wear of cutting tools during the orthogonal machining of carbon fiber reinforced polymers (CFRP). A novel measurement methodology and software toolbox is introduced for the measurement of the wear rate distribution along the edge of a cutting tool. The wear rate distribution is formulated to allow the development of an analytical wear rate model based on the Usui Wear Rate Model. This analytical wear rate model can generate wear rate distributions for a range of tool geometries and fiber cutting angles. The analytical wear rate model is coupled with an existing analytical force model via a tool wear simulation which uses the initial tool geometry and known cutting parameters to simulate the progression of tool wear and process forces during a cutting operation. The simulation revealed less than 10% error in the total volumetric wear attributed to the cutting edge of various tools.