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。生产率的提高往往伴随着热机械工具负荷的增加。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，工具概念需要关于工具负载的特定于应用程序的属性。然而，与工具加载相关的各种流程需要具有特定于应用程序的属性配置文件的工具概念。研究现状以及申请人自己的初步工作证明，通过有针对性的工艺和材料量身定做地调整刀具刃口的微观几何形状和涂层性能，可以显著提高涂层刀具的性能。涂层和刃口的微观几何形状都会影响由此产生的热机械刀具载荷。因此，对于涂层/基材化合物的优化设计，必须考虑整个系统和所发生的相互作用的识别。目前，还没有发现允许在考虑尖端微观几何形状的情况下设计涂层性能。在PVD涂料的生产中，特别是基于知识的特性调整对研究和工业提出了重要的挑战。用于涂层性能的定向修改的适当选项是相应的前处理和后处理。它们对残馀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。拟议研究项目的总体目标是获得关于涂层性能之间因果关系的基本结果，如涂层形态和厚度、刀具刃口微观几何形状以及连续和中断切割过程中产生的磨损和失效现象。这些发现被用于开发和验证基于模拟的PVD涂层硬质合金刀具的设计方法，该刀具具有合适的刃口微观几何形状。此外，还对涂层刀具生产工艺链对涂层/基材复合涂层性能的影响进行了基础研究。因此，这项建议的独创性包括开发一个模拟模型，用于设计具有适应的刀具刃口微观几何结构的涂层刀具，并推导出关于涂层刀具沉积的知识。

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.