Tool wear simulation of complex shaped coated cutting tools

In this paper FE-based tool wear simulation has been applied to complex shaped and coated cutting tools in turning operations. The coating has been considered by an own functional layer with specific friction and thermal properties as well as wear resistance. Therefore, a modified Usui tool wear model is calibrated for the coating and the substrate and combined in a three-dimensional simulation in order to simulate the wearing process including the baring of the substrate with a change in local thermal, friction and wear properties. Turning of AISI 1045 with PVD-TiAlN-coated and uncoated carbide tools was considered. The simulation results are validated by a comparison of simulated wear and external longitudinal turning experiments for a wide field of cutting parameters.