Influence of residual stresses in PVD-coatings on cutting performance in turning of AISI 4140

AlTiN and TiAlSiN coatings are effective wear protection methods for cutting tools due to their mechanical, thermal and chemical properties. Furthermore, residual stresses in coatings significantly affect the wear behavior of tools. The influence of varied residual stress state and its depth distributions in continuous and interrupted cut of AISI 4140 is investigated in this paper. The results show a significant influence of the coating residual stress states near the coating surface and near the interface on cutting performance. Especially in interrupted cutting processes, high compressive residual coating stresses near the interface lead to increased tool life due to prevented crack initiation.