Author(s): Luis Pereira, Anna Bergström and Mia Johansson

Abstract: Tool wear is a critical factor influencing the deformation characteristics and overall performance during the machining of hard-to-cut materials (HTCMs). In high-performance machining, such as in the aerospace, automotive, and medical industries, the ability to maintain high precision while minimizing material deformation is essential. As tools wear, their ability to cut efficiently declines, leading to higher forces, increased cutting temperatures, and material deformation. The impact of tool wear on deformation can be attributed to changes in cutting forces, tool geometry, and heat generation, which affect the workpiece surface integrity. This research investigates the relationship between tool wear progression and deformation in the machining of hard-to-cut materials (HTCMs). It examines the mechanisms through which tool wear influences material behavior and identifies the critical factors contributing to excessive deformation. The paper discusses the role of tool wear in altering the cutting forces and thermal characteristics, which, in turn, impact the workpiece's surface finish and dimensional accuracy. Additionally, the research highlights the significance of selecting the appropriate tool material and coating to minimize wear and reduce the deformation effects. Key experimental setups and models used to research these interactions are reviewed, and recommendations for improving tool performance are provided. The research aims to offer valuable insights into the optimization of machining parameters and tool selection to minimize the negative effects of tool wear on HTCMs. The findings of this research are expected to aid in improving the efficiency and sustainability of machining processes for these challenging materials.

DOI: 10.22271/27074544.2026.v7.i1a.76

Pages: 34-37 | Views: 22 | Downloads: 5

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