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Finite element investigation of cutting performance of Cr/W-DLC/DLC composite coated cutting tool

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Abstract

DLC has been applied as coating material in the machining of difficult-to-cut materials, and shows a good cutting performance. In this study, Cr/W-DLC/DLC-coated tools were compared with other three kinds of coated tools (TiC-, TiAlN-, Al2O3-) to investigate the cutting performance in the machining of Al–Si alloy. The influence of Cr/W-DLC/DLC-coated tools on the cutting performance under different cutting speeds was studied. Cutting force, cutting temperature, heat partition coefficient, cutting deformation rate, plastic deformation of machined surface, the interface temperature, and stress were investigated numerically with the aid of finite element method (FEM). Actual cutting experiments were carried out to verify the FEM models by means of the cutting force and cutting temperature measurement. The investigation results show that Cr/W-DLC/DLC-coated tool had the best cutting performance among these four kinds of coated tools. With the increasing of cutting speeds, cutting force and cutting temperature showed an increase trend, while the plastic deformation depth of machined surface and heat partition into cutting tool all showed a decrease trend during the machining with Cr/W-DLC/DLC-coated tool. This investigation can provide the theory basis or technical guidance for the cutting practice with Cr/W-DLC/DLC-coated tools.

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Funding

This work was supported by the National Natural Science Foundation of China (51675289, 51905286), the Natural Science Foundation of Shandong Province (ZR2020ME160), the Key Research and Development Plan of Shandong Province (2019GGX104052), and the Project for the Innovation Team of Universities and Institutes in **an (2018CXRC005).

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Authors and Affiliations

  1. School of Mechanical and Automotive Engineering, Qilu University of Technology (Shandong Academy of Sciences), **an, 250353, Shandong, China

    ** Du, Tianmei Hao, Xue Zhang, Guosheng Su, Peirong Zhang, Yu**g Sun, **gjie Zhang & Chonghai Xu

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  1. ** Du
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  2. Tianmei Hao
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  3. Xue Zhang
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  4. Guosheng Su
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  7. **gjie Zhang
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  8. Chonghai Xu
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Contributions

** Du contributed to the conception of the study; ** Du and Tianmei Hao performed the experiments and FE simulations. Xue Zhang, Guosheng Su, and Peirong Zhang contributed significantly to analysis and manuscript preparation; Yu**g Sun and **gjie Zhang helped perform the experiments and FE simulations. Chonghai Xu helped perform the analysis with constructive discussions.

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Correspondence to ** Du.

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Du, J., Hao, T., Zhang, X. et al. Finite element investigation of cutting performance of Cr/W-DLC/DLC composite coated cutting tool. Int J Adv Manuf Technol 118, 2177–2192 (2022). https://doi.org/10.1007/s00170-021-08093-0

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