Simulation-Based Design and Knowledge-Based Manufacturing of PVD-Coated Cutting Tools for Turning Operations - Schisi II

PVD-coated cutting tools are widely used in industrial manufacturing. When machining modern high-performance materials, these tools are subjected to increased thermomechanical loads, particularly under interrupted cutting conditions. Such cyclic loading leads to crack initiation, coating failure, and accelerated tool wear. As a consequence, tool costs increase, unplanned machine downtime occurs, and overall productivity decreases. 

At present, robust models that comprehensively represent the interactions between coating properties, cutting-edge microgeometry, and wear behavior are not available. Consequently, tool design is still largely performed through iterative and resource-intensive approaches. A knowledge-based, simulation-driven approach offers the potential to predict wear mechanisms more accurately and thereby unlock innovation potential and efficiency gains.

Objectives

The objective of the project is to develop a simulation-based methodology for the knowledge-driven design and manufacturing of PVD-coated cutting tools. By combining finite element simulations, experimental investigations, and process-analytical methods, the influence of cutting-edge microgeometry, the depth profile of residual stresses, and thermomechanical loading on wear behavior will be systematically characterized. 

The project will provide fundamental insights into the accurate representation of interrupted cutting processes and enable the development of optimized tool concepts that sustainably improve tool life, process reliability, and economic efficiency in industrial machining.

Benefits

• Reduced tool wear and decreased machine downtime
• Increased process reliability and extend tool life
• Cost savings through simulation-based development approaches
• Strengthening of innovation capability in manufacturing

Approach

The project is conducted in close collaboration between Leibniz University Hannover and RWTH Aachen University. Simulation experiments and finite element analyses are combined with experimental investigations for coating characterization. In this context, thermomechanical loading conditions, residual stresses, and the plastic behavior of the coating are modeled and experimentally validated. The objective is to derive knowledge-based correlations between coating parameters, cutting-edge microgeometry, and wear behavior. The results will be incorporated into a methodological guideline for the design of PVD-coated cutting tools.

Are you interested in innovative tool concepts or the simulation-driven design of coatings? 

Please contact Abdulmanem Aziza via email at aziza@ifw.uni-hannover.de or by telephone at +49 511 762 5207.