Examining Wear Patterns of Tools in Manufacturing Process

[engineer23]

I'm trying to study wear patterns of tools in a manufacturing process. My plan of attack is the following:
1) pre-image the tool in the SEM
2) use the tool to machine a superabrasive material
3) remove the excess Aluminum from the tool that accumulates during the machining process using NaOH
4) image the used/worn tool in the SEM to look for wear patterns and characterize how the wear pattern varies with process parameters


Does this sound reasonable? Is there a better way to do this?

I have previously done a study where I quantified the amount of wear by photographing the tool up-close and comparing pixel counts for the tool (pre and post use) in Photoshop. I am now trying to determine the wear mechanism (adhesion, abrasion, adhesion/abrasion. fretting, etc.)

 

[Navin A S]

by using the SEM to image the wear patterns at high magnification. Is this a valid approach or is there a better way?

 

[oswaler]

Your approach to studying wear patterns of tools in a manufacturing process seems reasonable. Using the SEM to image the tool before and after use can provide valuable insights into the wear patterns and how they vary with process parameters. Additionally, removing the excess Aluminum from the tool using NaOH can help to isolate the wear patterns and make them more visible for analysis.

However, I would suggest considering a few additional steps to enhance your study. First, it may be beneficial to use multiple tools and repeat the process with different superabrasive materials to see if the wear patterns are consistent across different materials. This can help to validate your findings and provide a more comprehensive understanding of the wear mechanisms.

Additionally, instead of relying solely on visual analysis, you could also consider using quantitative techniques such as surface profilometry or atomic force microscopy to measure the depth and extent of wear on the tool. This can provide more precise data and aid in identifying the specific wear mechanisms at play.

Overall, your proposed approach is a good starting point, but incorporating these additional steps can help to strengthen your study and provide more robust results.