Title: Numerical simulations of 3D tool geometry effects on deposition residual stresses in diamond coated cutting tools

Authors: Anderson Renaud, Jianwen Hu, Feng Qin, Y. Kevin Chou

Addresses: Mechanical Engineering Department, 290 Hardaway Hall, 7th Ave., The University of Alabama, Tuscaloosa, AL 35487, USA. ' Mechanical Engineering Department, 290 Hardaway Hall, 7th Ave., The University of Alabama, Tuscaloosa, AL 35487, USA. ' Mechanical Engineering Department, 290 Hardaway Hall, 7th Ave., The University of Alabama, Tuscaloosa, AL 35487, USA. ' Mechanical Engineering Department, 290 Hardaway Hall, 7th Ave., The University of Alabama, Tuscaloosa, AL 35487, USA

Abstract: Deposition residual stresses in diamond-coated cutting tools significantly impact the coating adhesion and machining performance. In this study, Computer-Aided Design (CAD) software was used to create the solid model of coated tools, and further exported to Finite Element Analysis (FEA) software for 3D simulations of residual stresses generated. Design of experiments approach was employed to systematically investigate the tool geometry effects. Major results are summarised as follows: the cutting edge radius is the most significant factor; for a 5 μm edge radius, the radial and circumferential normal stresses (σ_r and σ_θ) are about 1.5 GPa in tension and 3.7 GPa in compression, respectively.

Keywords: cutting tools; diamond coating; residual stresses; tool geometry; numerical simulation; coating adhesion; machining performance; CAD: finite element analysis; FEA; solid modelling.

DOI: 10.1504/IJMMS.2009.027132

International Journal of Mechatronics and Manufacturing Systems, 2009 Vol.2 No.4, pp.490 - 502

Published online: 15 Jul 2009 *

Full-text access for editors Full-text access for subscribers Purchase this article Comment on this article