To manufacture components with a certain pre-defined surface integrity, it is important to understand how tool wear affects the machined workpiece. In this work, an approach is proposed to simulate the effect of tool wear based on measured geometries of worn turning tools on process forces for different feeds. In orthogonal cutting simulations utilizing the Coupled Eulerian-Lagrangian (CEL) finite element method, forces are simulated and compared to cutting experiments. As input for the simulations, 3D tool geometries are decomposed into several 2D profiles. The results show a reasonable agreement of simulation and experiment laying the foundation for further analysis of surface integrity effects.
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