Influence of preparation-induced residual stresses in the cutting edge of cutting tools on the wear behavior of extremely hard cutting materials

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The cutting edge microgeometry has a significant influence on tool life. By preparation processes such as brushing, grinding or laser ablation of tools, this can be set in a targeted manner. The preparation processes significantly influences the residual stress condition and thus the tool life. In order to understand the influence of the preparation processes on the residual stress state, residual stress measurements in the influenced area of the cutting edge are necessary. Due to the very small measuring range, it is not possible to determine the residual stresses using X-ray methods. Raman microscopy is a method which offers measuring residual stresses locally in the cutting edge. After calibration of the measuring method by applying load stresses, PCD and PcBN tools will be prepared by grinding, laser ablation, brushing or EDM. The residual stress state is then determined using Raman microscopy and the tools are applied in turning experiments with AlSi10Mg or 100Cr6 to determine the influence of the residual stresses on tool life. The originality of the project is characterised by the establishment of a measuring method for the determination of local residual stresses directly in the cutting edge and their consideration in a machining simulation in order to obtain a deeper understanding of wear and failure mechanisms in the cutting materials PCD and PcBN.