Study of deformation of coated tools in orthogonal metal cutting process using FEA

The paper presents an investigation into the performance characteristics of electrical discharge machined cemented carbide tool inserts coated with titanium nitride (TiN). In this study, finite element analysis (FEA) software, SolidWorks CosmosExpress was used to study load bearing capacity of the cutting tool extensively. Results from cutting tests indicate increased tool life and better surface finish and reduce power loading by 18% when the tool was operated at 40% faster than the recommended standard speed. When the tool begins to wear out, tool wear characteristics did not affect dimensional accuracy of the work-piece. The surface enhancement, called „residual island‟ treatment, produces an undulating surface topography on the tool. As the tool wears, „islands‟ of residual titanium nitride remained in the valleys, which continued to provide wear resistance. It is expected that residual island effect would occur for most, if not all, types of coating. It was therefore concluded that TiN coatings if applied to turning tools with crater-like surface structures provide satisfactory lubricating properties which help in providing protection to the tool substrates against friction and wear