Dependence of tool wear on evolutionary changes in parameters of the dynamic cutting system

<jats:p>Introduction. A fundamental property of a dynamic cutting system (DCS) is its evolutionary change, caused by irreversible energy transformations in the machining zone. Within this process, the progression of tool wear acts as one of the factors influencing the evolution, while simultaneously being dependent on the state of the DCS. Consequently, wear depends on the parameters of the DCS, and the progression of wear alters the parameters of the dynamic coupling formed by cutting. In this interconnected, and therefore self-organizing, system, the intensity of wear becomes dependent on the initial parameters of the DCS, and the wear trajectory becomes dependent on the initial parameters of the system. However, to date, wear has not been considered as part of an interconnected set of subsystems. Subject. This study examines tool wear as an integral part of an evolutionarily changing cutting system, characterized by the interplay between its coordinates and wear. In particular, it investigates the patterns of change in wear trajectories as a function of the initial parameters of the cutting system. The aim of this study is to investigate the effect of irreversible energy transformations on tool wear in order to align it with the parameters of the DCS. Methods. This paper presents the results of mathematical modelling of the evolutionary changes in the properties of a DCS, which are determined by the phase trajectory of the power of irreversible energy conversions based on the work done. It examines a DCS model in which wear is described using Volterra’s equation, discusses the challenges of parameterizing the equations, presents the results of numerical modelling, and provides a practical example. Results and Discussion. The results of modelling the relationship between wear and DCS parameters, and control parameters (namely, machining conditions), are presented and discussed. An example is given of how the wear behavior changes during the turning of 0.1 C–1.0 Mn-2.0 Ni-0.3 Cu-0.7 V steel. It is demonstrated that the evolutionary properties of wear can be highly sensitive to small variations in the initial DCS parameters, disturbances, and control parameters. The problem of selecting the optimal cutting speed trajectory based on the work done by the forces is also considered, as well as the use of the developed mathematical tools to create a digital twin of the machining process.</jats:p>