Thermomechanical Coating Load in Dependence of Fundamental Coating Properties

Beblein, Sascha; Breidenstein, Bernd; Denkena, Berend; Pusch, Casper; Hoche, Holger; Oechsner, Matthias

doi:10.1016/j.procir.2017.03.184

Cited by 11 publications

(4 citation statements)

References 19 publications

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“…The workpiece was defined as an elasto-plastic body whose flow behavior is described as a function of strain, strain rate and temperature by the phenomenological material model according to Johnson and Cook [20] with the parameters according to [21]. The flow stress curves as well as the mechanical (Table 2) and thermal material data (Table 3) of the investigated material were taken from the material database of Software Deform.…”

Section: Simulation Setupmentioning

confidence: 99%

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FE-Simulation Based Design of Wear-Optimized Cutting Edge Roundings

Bergmann

Denkena

Beblein³

et al. 2021

JMMP

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The performance of cutting tools can be significantly enhanced by matching the cutting edge rounding to the process and material properties. However, the conventional cutting edge rounding design is characterized by a significant number of experimental machining studies, which involve considerable cost, time, and resources. In this study, a novel approach to cutting edge rounding design using FEM-based chip formation simulations is presented. Based on a parameterized simulation model, tool temperatures, stresses and relative velocities can be calculated as a function of tool microgeometry. It can be shown that the external tool loads can be simulated with high agreement. With the help of these loads and the use of wear models, the resulting tool wear and the optimum cutting edge rounding can be determined. The final experimental investigations show a qualitatively high agreement to the simulation, which will enable a reduced effort design of the cutting edge in the future.

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Section: Simulation Setupmentioning

confidence: 99%

“…In order to investigate the influence of different material properties, the friction parameters (Friction coefficient µ und shear friction factor m) were kept constant. The shear friction factor was set to m = 1 and the coefficient of friction to µ = 0.7 [21].…”

Section: Simulation Setupmentioning

confidence: 99%

FE-Simulation Based Design of Wear-Optimized Cutting Edge Roundings

Bergmann

Denkena

Beblein³

et al. 2021

JMMP

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“…The AlCrN and CrAlSiN coatings could be deponed using PVD methods in the temperature interval from 400 to 450 • C. For deposition of these coatings, the radiofrequency sputtering method [31,32] is rarely used-magnetron sputtering [33][34][35][36] is more frequently used. The cathodic arc deposition is the most significant method of PVD deposition for AlCrN and CrAlSiN coatings [37][38][39][40][41][42][43][44].…”

Section: Introductionmentioning

confidence: 99%

Wear of AlCrN and CrAlSiN Coatings Applied to Nonstandard Involute Gears

et al. 2021

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Wear of nonstandard involute gears with two types of coatings, AlCrN and CrAlSiN, was studied. The coatings were applied by cathodic arc deposition. The gears were tested using a Niemann tester at a graduated load up to the 12th load stage and were compared to noncoated gears. Both Biogear S150 gear oil and PP90 universal hydraulic oil were applied during these tests. The thickness of deposited coatings and wear of gear teeth were studied by SEM and their chemical compositions were determined by EDS analysis. Maximal contact pressure of 1350 MPa was calculated in the region of the tooth flank at the 12th load stage. Maximal frictional stress was also calculated on the tooth flank. The resistance against wear of gears was evaluated based on the critical weight loss and mainly based on the critical surface roughness of gears. The critical roughness was exceeded at the 10th load stage for noncoated gears. For the gears with AlCrN and CrAlSiN coatings, the critical roughness was exceeded at the 11th load stage. Wear of AlCrN and CrAlSiN coatings was nonuniform along the height of tooth. Wear on the tooth flank was characterized by fragmentation of thin coatings and subsequent detaching of fragments from the steel substrate. The steel substrate was worn by microcutting, which caused the highest roughness on the tooth surface. On the tooth pitch, surface protrusions of coatings were smoothed, and coatings cracked and locally detached subsequently. On the tooth face, surface protrusions were also smoothed but coatings remained compact without crack initiations. Both experimental oils, Biogear S150 and PP90, proved to be suitable during Niemann tests as their temperatures did not exceed the limit value of 80 °C.

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“…Beblein et al [82], created a FEM-2D model to study thermomechanical properties of coatings devoted to cutting tools. For the model fits as close as possible to the real problem, the coating properties were used, such as the physical and technological limits of CrAlN.…”

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confidence: 99%

Numerical Simulation Applied to PVD Reactors: An Overview

et al. 2018

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The technological evolution in the last century also required an evolution of materials and coatings. Therefore, it was necessary to make mechanical components subject to heavy wear more reliable, improving their mechanical strength and durability. Surfaces can contribute decisively to extending the lifespan of mechanical components. Chemical vapor deposition (CVD) and physical vapor deposition (PVD) technologies have emerged to meet the new requirements that have enabled a remarkable improvement in the morphology, composition and structure of films as well as an improved adhesion to the substrate allowing a greater number of diversified applications. Thin films deposition using PVD coatings has been contributing to tribological improvement, protecting their surfaces from wear and corrosion, as well as enhancing their appearance. This process can be an advantage over other processes due to their excellent properties and environmental friendly behavior, which gives rise to a large number of studies in mathematical modelling and numerical simulation, like finite element method (FEM) and computational fluid dynamics (CFD). This review intends to contribute to a better PVD process knowledge, in the fluids and heat area, using CFD simulation methods focusing on the process energy efficiency improvement regarding the industrial context with the sputtering technique.

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Thermomechanical Coating Load in Dependence of Fundamental Coating Properties

Cited by 11 publications

References 19 publications

FE-Simulation Based Design of Wear-Optimized Cutting Edge Roundings

FE-Simulation Based Design of Wear-Optimized Cutting Edge Roundings

Wear of AlCrN and CrAlSiN Coatings Applied to Nonstandard Involute Gears

Numerical Simulation Applied to PVD Reactors: An Overview

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