Abstract The hard coatings have proved very effective in industrial machining applications, and the development of new coatings relies more on simulations of the cutting process. In this regard, the present work investigates the machining performance of newly developed TiAlCrN multi-layered coating on tungsten carbide cutting tool during dry turning of AISI 1045 steel. A finite element model with damage evolution based on fracture energy was developed with the help of Abaqus/Explicit software. Later, the numerical results were validated by experimental measurements. The application of coating not only helped in the reduction of friction and tool temperatures at different cutting speeds but also affected the chip formation mechanism significantly. The secondary shear plane (SSP) was generated while machining with both uncoated and coated cutting tools. However, the SSP appeared only at higher cutting speeds in the case of the coated cutting tool. The proposed finite element model is able to predict the instability and formation of secondary serrated teeth with good accuracy.

中文翻译：

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一种二维有限元方法，用于预测 AISI 1045 钢干车削过程中 WC-Co 刀具上纳米层 TiAlCrN 涂层的加工性能

摘要 硬涂层已被证明在工业加工应用中非常有效，新涂层的开发更多地依赖于切削过程的模拟。在这方面，目前的工作研究了新开发的 TiAlCrN 多层涂层在 AISI 1045 钢干车削过程中碳化钨刀具上的加工性能。借助 Abaqus/Explicit 软件开发了基于断裂能的损伤演化有限元模型。后来，通过实验测量验证了数值结果。涂层的应用不仅有助于降低不同切削速度下的摩擦和刀具温度，而且显着影响切屑形成机制。二次剪切面 (SSP) 是在使用未涂层和涂层刀具进行加工时生成的。然而，在涂层刀具的情况下，SSP 仅在较高的切削速度下出现。所提出的有限元模型能够以良好的精度预测二次锯齿的不稳定性和形成。