International OPEN ACCESS Journal Of Modern Engineering Research (IJMER) | IJMER | ISSN: 2249–6645 | www.ijmer.com | Vol. 4 | Iss.11| Nov. 2014 | 35| Optimization of Tool Wear: A Review Ramakant Rana 1 , Kunal Rajput 2 , Rohit Saini 3 , Roop Lal 4 1 Assistant Professor, Mechanical and Automation Engineering, Maharaja Agrasen Institute of Technology, Delhi, India 2,3 Student, Mechanical and Automation Engineering, Maharaja Agrasen Institute of Technology, Delhi, India 4 Assistant Professor, Mechanical Engineering, Delhi Technological University, Delhi, India I. INTRODUCTION Research in metal cutting was started with Cocquilhat in 1851 which measured the work required to remove a given volume of material in drilling. The attempt made by Time led to the explanation of formation of chips in 1870 and further research was made by Tresca in 1873. Later in 1881, Mallock suggested that the cutting process was the shearing of workpiece to form the chip and emphasized the importance of the effect of friction occurring on the cutting tool face as the chip was removed. Further, Taylor investigated the effect of tool material and cutting conditions on tool life during rough operations. Latest fundamental work has been carried out by Ernst and Merchant in 1941 dealing with the mechanics of metal cutting process. The simplest and most widely used model for cutting was first by Ernest and Merchant (1941) and further contribution to study of Ernest and Merchant theory was done by Lee and Shaffer (1951), Kobayashi and Thomsen (1962). Large number of literature is available on the determination of chip-tool interface temperature, factors affecting the interface temperature and techniques of optimization of machining parameters including cutting speed, feed rate, cutting zone temperature, etc. Armerago (1969), Boothroyd (1981), Shaw (1984) and Trent (2000) wrote the most widely used text books. Kalpakjian, et al. (2006), and DeGarmo, et al. (1997) wrote books on more general introductory knowledge. The study machining process by experimental approach is expensive and time consuming peculiarly when a wide range of parameters is included like tool geometry, cutting conditions, and materials. II. LITERATURE REVIEW Jensen M.R. et al. [1] stated that an important problem in the machining of drawn parts is tool wear. They said that tool wear can be reduced by increasing the tool lifetime and by making more continuous production flow, by reducing the number of break-downs when the tools have to be re-polished. In their paper, an optimization of the shape of the draw-die profile with regard to wear was carried out using a conventional optimization method and explicit finite element. The optimized draw-die profile had almost twice the tool life compared to that of the initial circular draw-die, if the peak value of wear was used as the wear criteria. The relatively small resources used by them with their optimization approach made the tool wear design relevant for industrial use at the tool-design state. Sullivan D.O’ et al. [2] determined the temperature in a single point turning process. The total work done by a cutting tool in removing metal was determined from the force components on the cutting tool. Approximately, all of this work or energy is converted into heat which is dissipated into the chip, tool and workpiece material. The wear of the tool is related to the cutting forces. Initial experiments conducted involved the simultaneous measurement of forces and temperatures. These experiments focused on the use of embedded thermocouple (in the work piece) and using the infrared thermal camera to monitor the process. They concluded that in machining of aluminium Al 6082-T6 the decreased cutting tool forces and machined surface temperatures was resulted by increased cutting speed (V C ) and increased cutting tool forces and machined Abstract: The quality of the machined piece and tool life are greatly influenced by determination of maximum temperature of the cutting tool. Numerous researchers have approached to solve this problem with experimental, analytical and numerical analysis. There is hardly a consensus on the basics principles of the thermal problem in metal cutting, even though considerable research effort has been made on it. It is exceedingly difficult to predict in a precise manner the performance of tool for the machining process. This paper reviews work on the requirements for optimization of Tool wear so that its life could easily be predicted. Keywords: Tool Wear, Taguchi, CNC, Optimization, Wear.