Proposal for a new theoretical model of the cutting toolʹs flank wear

Based on studies of the physical characteristics of wear processes, the conclusion could be drawn that the cutting distance must be considered not only in abrasive and adhesive processes but also in thermally-activated diffusion and oxidation processes. Consequently, it can be proposed that a mathematical model of the rate of flank wear—an autonomous non-linear differential equation that takes into account the wear-accelerating effect of both the technological parameters of cutting and the temperature developing on the tool flank—can be applied. Furthermore, this model may be used to calculate the tool life and the Taylor formula related to any arbitrarily chosen failure criteria. Technological parameters may also change periodically or continuously depending on time. The constants of the wear equation and the apparent activation energy of the process can be determined by cutting experiments and also by measurements of wear performed during factory manufacturing under a variety of technological parameters. The complex wear equation was validated by the cutting tests performed with P20 carbide on AISI1045 carbon steel. The adverse effect of rapidly changing cutting speed on the wear of the tool during vibration could be modelled.