LAUSR

Abstract The hard coatings have proved very effective in industrial machining applications, and the development of new coatings relies more on simulations of the cutting process. In this regard, the present work investigates the machining performance of newly developed TiAlCrN multi-layered coating on tungsten carbide cutting tool during dry turning of AISI 1045 steel. A finite element model with damage evolution based on fracture energy was developed with the help of Abaqus/Explicit software. Later, the numerical results were validated by experimental measurements. The application of coating not only helped in the reduction of friction and tool temperatures at different cutting speeds but also affected the chip formation mechanism significantly. The secondary shear plane (SSP) was generated while machining with both uncoated and coated cutting tools. However, the SSP appeared only at higher cutting speeds in the case of the coated cutting tool. The proposed finite element model is able to predict the instability and formation of secondary serrated teeth with good accuracy.