Finite element modeling and simulation of orthogonal cutting with multi layer coated tools

Abstract EN

This paper focuses on the development of Finite Element Method (FEM) in modeling and simulation of coated cutting tools with multi-layer coats.

A special Finite Element code called (MSC.MARC mentat) is used in the numerical tests, the results are then compared with experimental work.

The paper studied the effect of number of coats of cutting tools on the following field parameters; tool-chip contact length, chip contraction coefficient and shear angle at similar machining conditions.

The metal being machined is (AISI 1045 steel) with orthogonal machining conditions.

The three cutting tools and models are coated with (TiN, TiN / TiC, TiN / Al2O3 / TiC), while the fourth one is uncoated.

The results show good agreement between the experimental and numerical tests.

Some of the results are compared with other published papers.

The comparison of the predicted results shows good agreement with experimental tests with maximum relative difference of (18 %) for the chip contraction coefficient and contact length, and (10 %) for the shear angle.

The insert with double coats shows excellent result, compared to others from point of view of chip contraction coefficient, contact length and shear angle.