Abstract
Coated carbide tools are widely used in machining titanium alloys due to their excellent wear resistance, high strength, and hardness even at elevated temperature. The paper gives a special attention to the failure mechanisms of coated carbide cutting tools during high-speed intermittent cutting process. The effects of serrated chip formation on the instantaneous cutting forces, transient temperature, and thermal stress distributions on the cutting tool were investigated based on finite element method (FEM). The results show that the cutting tools undergo combined thermomechanical and high/low cycle fatigue loading during intermittent cutting process. Micro-crack propagation and coating delamination were observed on the cutting edge and rake face. Flank wear and brittle fractures on the cutting edge caused by crack propagation were identified as the main failure mode of coated carbide tools in intermittent cutting process. Intense tensile thermal stress on the cutting tool edge was found to be produced by differential cooling rates in the idle periods. The rapid alteration of stresses was believed to be the direct cause of crack propagation on the cutting edge.
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