Basic investigations for simulative design and knowledge-based production of PVD-coated cutting tools for turning

工具和技术概念发展的驱动力是使用新的高强度材料以及追求更高的经济效益。生产率的提高通常伴随着热机械工具负载的增加。在过去的几十年里，涂层的应用已经建立起来，以提高切削刀具的性能。可以肯定地说，涂层现在属于最先进的技术。由于工艺的多样性，刀具概念需要与刀具载荷有关的特定应用特性。然而，关于工具负载的各种过程需要具有特定于应用的属性简档的工具概念。研究状况以及申请人自己的初步工作证明，涂层切削工具的性能可以通过切削刃微观几何形状和层性质的有针对性的工艺和材料定制调整而显著提高。涂层和切削刃的微观几何形状都会影响所产生的热机械工具载荷。因此，对于涂层/基材复合物的优化设计，必须考虑整个系统和对发生的相互作用的识别。目前，还没有发现允许考虑切削刃微观几何形状的涂层性能设计。在PVD涂层的生产中，特别是基于知识的特定性能调整对研究和工业提出了重要挑战。涂层性能的目标改性的合适选择是相应的预处理和后处理。它们对残余应力深度分布与涂层厚度等其他涂层性能之间的相互关系的影响还没有得到充分的研究。拟议的研究项目的总体目标包括涂层性能之间的因果关系的基本发现的可用性，如涂层形态和厚度，切削刃微观几何形状和由此产生的磨损以及连续和中断切削过程中的故障现象。这些研究结果被用于开发和验证的基于模拟的设计方法的PVD涂层硬质合金刀具与适应的切削刃微观几何形状。此外，基本的调查进行的涂层刀具的生产过程链上的复合涂层/基体的性能的影响。因此，该提案的独创性包括开发用于设计具有自适应切削刃微观几何形状的涂层切削刀具的仿真模型以及推导关于其沉积的知识。

Driving forces for the development of tool and technology concepts are the use of new, high-strength materials as well as the pursuit of higher economic efficiency. The increase in productivity is often accompanied by an increase of the thermomechanical tool load. Over the last decades, the application of coatings has been established to improve the performance of cutting tools. It is safe to say coatings now belong to the state of the art. Due to the variety of processes, tooling concepts require application-specific properties regarding tool load. However, the variety of processes with regard to the tool load requires tool concepts with application-specific property profiles. The state of research as well as the applicant's own preliminary work prove that the performance of coated cutting tools can be significantly increased by means of the targeted process and material tailored adjustment of the cutting edge microgeometry and the layer properties. Both coating and cutting edge micro-geometry influence the resulting thermomechanical tool load. Therefore, the overall system and the identification of the occurring interaction have to be taken into consideration for an optimized design of the coating/substrate compound. Currently, there are no findings which allow the design of coating properties in consideration of the cutting edge micro-geometry. In the production of PVD-coatings, especially the knowledge-based adjustment of specific properties presents an important challenge for research and industry. Suitable options for the targeted modifications of the coating properties are corresponding pre- and post-treatments. Their influence on the interrelation between the residual stress depth profile and other coating properties such as coating thickness has not been sufficiently explored yet. The overall aim of the proposed research project consists of the availability of basic findings about the cause-effect relationships between coating properties, like coating morphology and thickness, cutting edge micro-geometry and the resulting wear as well as failure phenomena during continuous and interrupted cutting. These findings are used for the development and validation of a simulation-based design method for PVD-coated cemented carbide tools with an adapted cutting edge micro-geometry. In addition, basic investigations are carried out on the influence of the process chain of the production of coated cutting tools on the resulting properties of the compound coating/substrate. Thus, the originality of this proposal consists of the development of a simulation model for the design of coated cutting tools with adapted cutting edge micro-geometry as well as the derivation of knowledge about their deposition.