Skip to main content
SpringerLink
Log in

Design and simulation of thermal residual stresses of coatings on WC-Co cemented carbide cutting tool substrate

  • Published:
Journal of Mechanical Science and Technology Aims and scope Submit manuscript

Abstract

Large thermal residual stresses in coatings during the coating deposition process may easily lead to coating delamination of coated carbide tools in machining. In order to reduce the possibility of coating delamination during the tool failure process, a theoretical method was proposed and a numerical method was constructed for the coating design of WC-Co cemented carbide cutting tools. The thermal residual stresses of multi-layered coatings were analytically modeled based on equivalent parameters of coating properties, and the stress distribution of coatings are simulated by Finite element method (FEM). The theoretically calculated results and the FEM simulated results were verified and in good agreement with the experimental test results. The effects of coating thickness, tool substrate, coating type and interlayer were investigated by the proposed geometric and FEM model. Based on the evaluations of matchability of tool substrate and tool coatings, the basic principles of tool coating design were proposed. This provides theoretical basis for the selection and design of coatings of cutting tools in high-speed machining.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. J. X. Deng and J. Zhao, NC cutting tool materials selection handbook, China Machine Press, Beijing, China (2005).

    Google Scholar 

  2. K. D. Bouzakis, N. Michailidis, G. Skordaris, E. Bouzakis, D. Biermann and R. M'Saoubi, Cutting with coated tools: Coating technologies, characterization methods and performance optimization, CIRP Annals-Manufacturing Technology, 61 (2) (2012) 703–723.

    Article  Google Scholar 

  3. Z. Nibennaoune, D. George, S. Ahzi, D. Ruch, Y. Remond and J. J. Gracio, Numerical simulation of residual stresses in diamond coating on Ti-6Al-4V substrate, Thin Solid Films, 518 (12) (2010) 3260–3266.

    Article  Google Scholar 

  4. U. Wiklund, J. Gunnars and S. Hogmark, Influence of residual stresses on fracture and delamination of thin hard coatings, Wear, 232 (2) (1999) 262–269.

    Article  Google Scholar 

  5. K. D. Bouzakis, S. Hadjiyiannis, G. Skordaris, I. Mirisidis, N. Michailidis, K. Efstathiou, E. Pavlidou, G. Erkens, R. Cremer, S. Rambadt and I. Wirth, The effect of coating thickness, mechanical strength and hardness properties on the milling performance of PVD coated cemented carbides inserts, Surface and Coatings Technology, 177 (2004) 657–664.

    Article  Google Scholar 

  6. S. H. I. Jaffery and P. T. Mativenga, Wear mechanisms analysis for turning Ti-6Al-4V—towards the development of suitable tool coatings, International Journal of Advanced Manufacturing Technology, 58 (5–8) (2012) 479–493.

    Article  Google Scholar 

  7. V. Luzin, K. Spencer and M. X. Zhang, Residual stress and thermo-mechanical properties of cold spray metal coatings, Acta Materialia, 59 (3) (2011) 1259–1270.

    Article  Google Scholar 

  8. T. Nomura, H. Moriguchi, K. Tsuda, K. Isobe, A. Ikegaya and K. Moriyama, Material design method for the functionally graded cemented carbide tool, International Journal of Refractory Metals and Hard Materials, 17 (6) (1999) 397–404.

    Article  Google Scholar 

  9. Z. Q. Huang, Y. H. He, H. T. Cai, Y. F. Xiao and B. Y. Huang, Finite element analysis of thermal residual stresses at cemented carbide rock drill buttons with cobalt-gradient structure, Transactions of Nonferrous Metals Society of China, 18 (3) (2008) 660–664.

    Article  Google Scholar 

  10. S. A. Hussein, A. S. M. Tahir and R. Izamshah, Generated forces and heat during the critical stages of friction stir welding and processing, Journal of Mechanical Science and Technology, 29 (10) (2015) 4319–4328.

    Article  Google Scholar 

  11. Z. Arabgol, H. Assadi, T. Schmidt, F. Gärtner and T. Klassen, Analysis of thermal history and residual stress in coldsprayed coatings, Journal of Thermal Spray Technology, 23 (1–2) (2014) 84–90.

    Article  Google Scholar 

  12. K. Narasimhan, S. P. Boppana and D. G. Bhat, Development of a graded TiCN coating for cemented carbide cutting tools—a design approach, Wear, 188 (1) (1995) 123–129.

    Article  Google Scholar 

  13. W. Grzesik, Composite layer-based analytical models for tool-chip interface temperatures in machining medium carbon steels with multi-layer coated cutting tools, Journal of Materials Processing Technology, 176 (1–3) (2006) 102–110.

    Article  Google Scholar 

  14. L. Y. Zhou, J. T. Ni and Q. D. He, Study on failure mechanism of the coated carbide tool, International Journal of Refractory Metals and Hard Materials, 25 (1) (2007) 1–5.

    Article  Google Scholar 

  15. Y. Pauleau, Generation and evolution of residual stresses in physical vapour deposited thin films, Vacuum, 61 (2001) 175–181.

    Article  Google Scholar 

  16. C. V. Falub, A. Karimi, M. Ante and W. Kalss, Interdependence between stress and texture in arc evaporated Ti-Al-N thin films, Surface and Coatings Technology, 201 (12) (2007) 5891–5898.

    Article  Google Scholar 

  17. H. O. Pierson, CVD in wear-and corrosion-resistant applications, Handbook of Chemical Vapor Deposition (CVD), Principles, Technology, and Applications, Second Ed., William Andrew Inc., Norwich, USA (1999).

    Google Scholar 

  18. J. W. Yan, Y. Murakami and J. P. Davim, Tool design, tool wear and tool life, Machining Dynamics, Springer, London, British (2009) 117–149.

    Chapter  Google Scholar 

  19. A. H. Li, Design and manufacturing of coated carbide tools based on tool failure evolution in high speed milling of Titanium alloy, Ph.D. Thesis, Shandong University, Jinan, China (2013).

    Google Scholar 

  20. S. Hogmark, S. Jaocbson, M. Larsson and U. Wiklund, Mechanical and tribological requirements and evaluation of coating composites, Modern Tribology Handbook, CRC Press, Florida, USA, 1 (2000).

    Google Scholar 

  21. R. Ali, M. Sebastiani and E. Bemporad, Influence of Ti-TiN multilayer PVD-coatings design on residual stresses and adhesion, Materials & Design, 75 (2015) 47–56.

    Article  Google Scholar 

  22. P. C. Jindal, A. T. Santhanam, U. Schleinkofer and A. F. Shuster, A Performance of PVD TiN, TiCN, and TiAlN coated cemented carbide tools in turning, International Journal of Refractory Metals and Hard Materials, 17 (1) (1999) 163–170.

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Key Laboratory of High Efficiency and Clean Mechanical Manufacture of MOE, School of Mechanical Engineering, Shandong University, Jinan, 250061, China

    Anhai Li, Jun Zhao, Jian Zang & Wei Zheng

  2. Zhejiang Provincial Key Laboratory for Cutting Tools, Taizhou University, Taizhou, 318000, China

    Anhai Li

Authors
  1. Anhai Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Jun Zhao
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Jian Zang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Wei Zheng
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Jun Zhao.

Additional information

Recommended by Associate Editor Hyung Wook Park

Anhai Li, born in 1984, is currently an Assistant Professor at School of Mechanical Engineering, Shandong University, Jinan, China. He received his B.E. degree in Mechanical Engineering and Automation from Jilin University, Changchun, China in 2008 and his Ph. D. degree in Mechanical Manufacturing and Automation from Shandong University, Jinan, China in 2013. His research interests include high efficient machining and numerical control cutting tool technology. He is the member of American Society of Mechanical engineers (ASME) and Chinese mechanical engineering society (CMES).

Jun Zhao, born in 1967, is currently a Professor at School of Mechanical Engineering, Shandong University, Jinan, China. He received his B.E. degree, M. E. degree and Ph.D. degree in Mechanical Engineering from Shandong University of Technology, Jinan, China in 1989, 1993 and 1998, respectively. His research interests include high efficient machining & NC tool technology and multi-axis CNC machining technology of complex curved surface. He is the member of Chinese mechanical engineering society (CMES).

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Li, A., Zhao, J., Zang, J. et al. Design and simulation of thermal residual stresses of coatings on WC-Co cemented carbide cutting tool substrate. J Mech Sci Technol 30, 3777–3783 (2016). https://doi.org/10.1007/s12206-016-0430-0

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12206-016-0430-0

Keywords

Search

Navigation