Multidomain Grey Box based assistant for tool coating selection in high performance milling [MultiDomHPC]

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In recent decades, considerable progress has been made in all sub-disciplines of machining, for example in the simulation of cutting processes, in the design of tools and machine tools, or in the coating of tools with wear-resistant hard material coatings. R&D work in manufacturing technology is very closely interlinked with the field of tribology, particularly with regard to studies on the wear behavior of tools. The interactions between tool and workpiece during machining are of such a complex nature that cooperation between different disciplines is necessary to clarify them. This application will therefore use expertise from the fields of tribology, coating technology, materials science and manufacturing technology to work together on this topic. In particular, the focus is on understanding the wear behavior of coated tools as a function of the stress spectrum, in order to be able to make a knowledge-based tool/coating selection in the future that leads to higher component surface qualities and tool life. The industrial standard in the machining of metals with geometrically defined cutting edges are tools with a hard coating that significantly increases tool life. Since this highly wear-resistant coating is exposed to high temperatures and sliding speeds during machining, wear results in a chemical and mechanical change in the hard coating and complex tribological behavior. Today, this behavior can only be insufficiently described multiscale by simulation, since the effect of all possible influencing variables is not completely understood, and therefore usually does not allow a precise evaluation and prediction of the wear condition of the coated tools in the context of machining. With the results of this research work, it will be possible to predict the suitability of a tool coating for any kind of process parameter combination and workpiece material-tool combination in the HPC process. This leads to an optimization of the tool use, a reduction of the tool wear and at the same time an increased productivity.