Effect of structure and residual stresses of diamond coated cemented carbide tools on the film adhesion and developed wear mechanisms in milling

This article deals with the wear mechanisms of variously adherent nano-composite or multi-layer diamond coated tools in milling. The adhesion and residual stresses of these films on cemented-carbide inserts were characterized via inclined impact tests at diverse temperatures. The obtained results were evaluated through FEM-supported mathematical methods for estimating the maximum film residual stress and the shear failure stress (SFLS) of the coating-substrate interface. The coated inserts were used in milling AA7075 T6. The developed wear mechanisms were elucidated considering the film structure, the defined temperature-dependent SFLS and the FEM-determined stress and temperature distribution in the tool wedge region during cutting.