Abstract
Automotive companies in highly industrialized regions are currently facing a stronger competitive situation than ever before. With the onset of Industry 4.0, digitalization of the production systems has been a trendsetter. Due to fast changing markets and push for implementing novel materials, the competitiveness relies increasingly on economical and short planning cycles of machining processes. This has increased the application of simulation tools such as the Finite Element Method (FEM) in manufacturing technologies, including machining. In the last decade, various researchers applied FEM to simulate the macro- and micro- geometry of tools. Furthermore, FEM has been implemented to analyze the effect of coating thickness but has been widely limited to 2D-simulations. In future, a 3D-FEM simulation analyzing the effects of coating thickness in machining can significantly shorten the development cycle, as the simulation can be directly implemented for optimization of mass-production processes. This work presents a 3D-finite element model of a turning operation using AlTiN coated tools with two different coating thicknesses of 4 µm and 8 µm. The Finite Element Method (FEM) simulations are conducted in AdvantEdge software. The influence of coating thicknesses on temperature, and forces are simulated in coating and substrate for a hard to machine casted steel alloy, 1.4837D. The experimental temperature is measured with a two-color pyrometer and the forces are measured with a 3-component dynamometer. In the end, simulated results such as forces and temperature are compared to the experimental measurements and the comparison demonstrates a good agreement between them.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
Komanduri, R., Raff, L.M.: A review on the molecular dynamics simulation of machining at the atomic scale. SAGE J. 215, 1639–1672 (2001)
Taylor, F.W.: On the art of Cutting metals. Trans. ASME 28, 31–248 (1907)
Athavale, S.M., Strenkowski, J.S.: Finite element modelling of machining: from proof-of-concept to engineering applications. Mach. Sci. Technol. 2, 317–342 (1998)
Usui, E., Shirakashi, T.: Mechanics of machining-from “descriptive” to “predictive” theory. ASME 7, 13–35 (1982)
Strenkowski, J.S., Carroll III, J.T.: A finite element model of orthogonal metal cutting. J. Manuf. Sci. Eng. 107, 349–354 (1985)
Marusich, T.D., Ortiz, M.: Modelling and simulation of high speed machining. Int. J. Numer. Method Eng. 38, 3675–3694 (1995)
Limido, J., Espinosa, C., Salaun, M., Lacome, J.L.: A new approach of high speed cutting modelling: SPH method. J. Phys. IV 134, 1195–1200 (2006)
Limido, J., Espinosa, C., Salaün, M., Lacome, J.L.: SPH method applied to high speed cutting modelling. Int. J. Mech. Sci. 49, 898–908 (2007)
Rana, P., Zielasko, W., Schuster, T., Hintze, W.: Orthogonal turning simulations for casted steel alloy using mesh free methods. In: Production at the Leading Edge of Technology, pp. 337–346 (2019)
Ruppi, S.: Advances in chemically vapor deposited wear resistance coatings. J. Phys. IV France 11, 847–859 (2001)
PalDey, S., Deevi, S.C.: Single layer and multilayer wear resistant coatings of (Ti, Al)N: a review. Mater. Sci. Eng. 342, 58–79 (2003)
M’Saoubi, R., Ruppi, S.: Wear and thermal behavior of CVD α-Al2O3 and MTCVD Ti(C, N) coatings during machining. CIRP Ann. 58, 57–60 (2009)
Grzesik, W.: Experimental investigation of the cutting temperature when turning with coated indexable inserts. Int. J. Mach. Tools Manuf. 39, 355–369 (1999)
Grzesik, W., Bartoszuk, M., Nieslony, P.: Finite element modelling of temperature distribution in the cutting zone in turning processes with differently coated tools. J. Mater. Process. Technol. 164–165, 1204–1211 (2005)
Kone, F., Czarnota, C., Haddag, B., Nouari, M.: Finite element modelling of the thermo-mechanical behavior of coatings under extreme contact loading in dry machining. Surf. Coat. Technol. 205, 3559–3566 (2011)
Krajinović, I., et al.: Finite element study of the influence of hard coatings on hard metal tool loading during milling. Surf. Coat. Technol. 304, 134–141 (2016)
Sargade, V.G., Gangopadhyay, S., Paul, S., Chattopadhyay, A.K.: Effect of coating thickness on the characteristics and dry machining performance of TiN film deposited on cemented carbide inserts using CFUBMS. Mater. Manuf. Process. 26, 1028–1033 (2011)
Kumar, C.S., Patel, S.K.: Experimental and numerical investigations on the effect of varying AlTiN coating thickness on hard machining performance of Al2O3-TiCN mixed ceramic inserts. Surf. Coat. Technol. 309, 266–281 (2017)
Kumar, C.S., Patel, S.K.: Investigations on the effect of thickness and structure of AlCr and AlTibased nitride coatings during hard machining process. J. Manuf. Process. 31, 336–347 (2018)
Kaiser, T.: Entwicklung eines Nickel-reduzierten Austenits als Werkstoff im thermisch hoch beanspruchten Abgasturbolader. Dissertation Universität Clausthal (2014)
Kumar, V., Penich, R.: Stabilization of cubic phase in AlTiN coatings using anode configurations. Int. J. Refract. Metals Hard Mater. 60, 113–117 (2016)
Acknowledgements
The authors would like to thank Mr. Marco Hinrichs from IPMT for helping in conducting the experiments and company Ceratizit for providing the tools.
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2022 The Author(s), under exclusive license to Springer Nature Switzerland AG
About this paper
Cite this paper
Rana, P., Hintze, W., Schall, T., Polley, W. (2022). Study on the Influence of the Coating Thickness in Turning of a Hard to Machine Material Using FEM-Simulation. In: Behrens, BA., Brosius, A., Drossel, WG., Hintze, W., Ihlenfeldt, S., Nyhuis, P. (eds) Production at the Leading Edge of Technology. WGP 2021. Lecture Notes in Production Engineering. Springer, Cham. https://doi.org/10.1007/978-3-030-78424-9_29
Download citation
DOI: https://doi.org/10.1007/978-3-030-78424-9_29
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-030-78423-2
Online ISBN: 978-3-030-78424-9
eBook Packages: EngineeringEngineering (R0)