Studies on the effect of cutter wear on cutting dynamics when turning Sergey Timofeev, Andrey Savilov ⇑ , Alexey Pyatykh Irkutsk National Research Technical University, 83 Lermontov st., Irkutsk 664047, Russia article info Article history: Received 6 May 2020 Accepted 7 August 2020 Available online xxxx Keywords: Turning Tool wear Cutting forces Cutting power Aluminum alloys abstract The article describes the study of cutting dynamics using tools with hard material brazed inserts. Thrust cutters were used as cutting tools. The samples were made of deformable aluminum alloy V95, which is widely used in the aircraft manufacturing industry. Machinability of an aluminum alloy by the cutting method and cutting problems were analyzed. A CNC turning center was used. The influence of cutting edge wear on output turning parameters (cutting force and cutting power) was analyzed. The experiment was conducted on the basis of a three-factor, three-level non-compositional Box-Behnken design. During the experiments, the influence of cutting speed, tool feed and cutting edge wear on cutting forces and cutting power was determined. A wear criterion based on acceptable cutting dynamics was determined. Ó 2020 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the International Confer- ence on Modern Trends in Manufacturing Technologies and Equipment 2020. 1. Introduction Turning is one of the most common edge cutting processes. Accordingly, the problem of improving efficiency of turning is rel- evant. The main studies are aimed at improving productivity, achieving target surface roughness, and suppressing vibrations during cutting [1–5]. It is necessary to use cutting tools effectively and determine their economically viable durability. The basis of these works is a study of cutter wear mechanisms [6–10]. Wear influences tool life and cutting dynamics. With increasing wear, cutting forces increase leading to an increase in cutting power and torque. This increases load on technological systems, primarily on spindles. In addition, it is necessary to determine the possibility of implementing specified cutting data. In most cases, cutting data are specified by tool manufacturers, using electronic manuals or special software, without taking into account cutter wear. This applies to turning and other tools. At the same time, along with depth of cut, feed and cutting speed, cutting power and torque are calculated. Calculated power and torque are compared with a spindle diagram to prevent machine tools overload. However, with increased cutter wear, cutting power and torque can increase to critical values, resulting in cutter breakage. Therefore, the depen- dence of output turning parameters with wear on the cutting tool on cutting modes should be studied. Materials used by the authors studying the turning process are structural steels and hard-to-machine materials (e.g., titanium and heat-resistant super alloys) [3,4,6]. Structural steels are the most common materials used in mechanical engineering, and the turn- ing of hard-to-machine materials is labor intensive and costly. At the same time, little attention is paid to aluminum alloys. Although aluminum alloys have good machinability and are less hard than hard-to-machine materials, the turning is accompanied by a num- ber of problems [12–15]. One of the biggest problems is vibrations [11]. To some extent, probability of vibrations when turning alu- minum is higher than when turning other metals due to high cut- ting speeds and the reduced damping effect. There are studies aimed at determining machinability of mate- rials by calculating coefficients of cutting forces based on experi- mental data. The experimental data are obtained using the orthogonal turning method [16]. Although the results of these studies are not directly used in the industry, they are significant for a number of fields, including Modal analysis of technological systems. It can be concluded that the study of a wear effect on cutting dynamics when turning aluminum alloys is relevant. The aim of this research is to determine experimental dependences of cutting forces and cutting power on cutter wear under various cutting modes. 2. Materials and methods To perform the experiments, deformable aluminum alloy V95 was used. This alloy is widely used in the aircraft industry for man- ufacturing parts of a power frame. A bar with a diameter of 55 mm https://doi.org/10.1016/j.matpr.2020.08.105 2214-7853/Ó 2020 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the International Conference on Modern Trends in Manufacturing Technologies and Equipment 2020. ⇑ Corresponding author. Materials Today: Proceedings xxx (xxxx) xxx Contents lists available at ScienceDirect Materials Today: Proceedings journal homepage: www.elsevier.com/locate/matpr Please cite this article as: S. Timofeev, A. Savilov and A. Pyatykh, Studies on the effect of cutter wear on cutting dynamics when turning, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.08.105