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

通过PVD（物理气相沉积）硬质涂层对切削刀具进行涂覆，可显著提高刀具寿命和生产率。在许多情况下，由于薄膜的隔热效果以及摩擦系数的降低，可以省略润滑剂的使用。根据不同的切削加工类型，定制的PVD涂层可以通过对涂层性能（如硬度、抗氧化性、摩擦系数和扩散性）的特殊设计来提高刀具的使用寿命。对这些涂层的要求根据所要执行的任务而有所不同，并受待加工材料、加工参数和加工刀具的总体几何形状的影响。如今，用于特定切割任务的涂层系统的常规开发包括具有精细实验参数研究的各种测试系列。特别是，在实际实验中的切削行为的调查导致显着的resources，时间和costs.The拟议的研究项目的目标是通过使用有限元模拟优化与PVD硬质涂层干加工刀具的开发过程。因此，将进行基于CrAl（X）N干式切削操作的涂层系统的模拟辅助合成的基本概念研究。使用部件-刀具接触的磨损模拟将由PVD涂层补充。通过调整PVD合成参数实现了基于有限元模拟的层性能的规范，并进行了实验验证。通过有限元模拟、PVD涂层合成、性能曲线的基本表征和干切削实验之间的相互作用，涂层系统的开发过程将得到显著优化。

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.