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Coated tools wear prediction in milling explained by the strain rate affected film fatigue failure

: Bouzakis, K.D.; Paraskevopoulou, R.; Makrimallakis, S.; Katirtzoglou, G.; Bozakis, E.; Efstathiou, K.

Bouzakis, K.-D.:
10th International Conference The ''A'' Coatings 2013. Proceedings : 10 - 11 April 2013, Aachen
Aachen: Shaker, 2013 (IOT - Schriftenreihe Oberflächentechnik 27)
ISBN: 978-3-8440-1781-6
International Conference THE "A" Coatings in Manufacturing Engineering <10, 2013, Aachen>
Conference Paper
Fraunhofer IPT ()

The knowledge of coated tool wear mechanisms in milling is central for explaining the film failure and selecting the appropriate cutting strategy and conditions. The described tool wear investigations in up and down milling were carried out for various cutting conditions, by coated cemented carbide inserts fixed on tool holders of different diameters. The variable stress, strain and strain rate fields developed in the tool during cutting, affect the filmsubstrate deformation and in this way the resulting coating's loads and its fatigue failure. The effective tool life, up to a certain flank wear width was experimentally determined and correlated to the cutting edge entry impact duration (CEEID) into the workpiece material. Using a commercial CAD/CAM system, the geometry of the chip and of the contact between the cutting edge and workpiece was calculated in various milling cases and the corresponding tool wear evolution predicted. The latter converges with CEEID and with the associated film fatigue critical force, affected by the coating strain rate.