Optimizing of PVD coatings for dry cutting applications by FE-simulation

• Applicants: Professor Dr. Bernd Breidenstein; Dr.-Ing. Holger Hoche
• Subject Area: Coating and Surface Technology ; Mechanical Properties of Metallic Materials and their Microstructural Origins
• Term: from 2014 to 2018
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 258383513

The coating of cutting tools by means of PVD (physical vapor deposition) hard coatings increases the tool life and productivity significantly. In many cases, use of lubricants can be omitted due to the thermal barrier effect of the films as well as reduction of the coefficient of friction. Depending on the type of cutting operation, individually tailored PVD coatings can improve tool life time by specific design of coating properties such as hardness, oxidation resistance, friction coefficient and diffusivity.The requirements for these coatings vary according to the task to be performed and are influenced by the material to be machined, the machining parameters and the total geometry of the machining tool. Today, a conventional development of a coating system for a specific cutting task includes a variety of test series with elaborate experimental parameter studies. In particular, the investigation of the cutting behaviour in practical experiments causes significant ressources, time and costs.The goal of the proposed research project is to optimize the development process of cutting tools with PVD hard coatings for dry machining through the use of FE simulations. Therefore, fundamental conceptual studies concerning the simulation assisted synthesis of coating systems on the basis of CrAl(X)N dry machining operation will be conducted.The wear simulation using component - tool contact will be supplemented by the PVD coating. The specifications of the layer properties on basis of FE simulations are realized by adjustment of the PVD synthesis parameters and experimentally verified. From the interaction between FE simulation, synthesis of PVD coatings, fundamental characterization of property profiles and dry cutting experiments the development process of coating systems will be significantly optimized.

• DFG Programme: Research Grants