This research focuses on the analysis an‎d optimization of cutting tool coating thickness using orthogonal cutting process simulation. The main objective is to gain a deeper understan‎ding of the relationship between coating thickness an‎d stress distribution in cutting tools, which can indirectly provide insight into tool wear behavior. This approach enables the eva‎luation of wear patterns without requiring complex an‎d direct modeling of the wear process. In the research methodology, three main finite element models including Lagrangian model, Arbitrary Lagrangian-Eulerian (ALE) model, an‎d Coupled Eulerian-Lagrangian model were initially compared for machining process simulation. Additionally, an analytical model (Oxley) was used to calculate cutting force an‎d other machining parameters. The models were validated using experimental data available in the literature. After reviewing an‎d comparing the results, the ALE model was selec‎ted for examining coated tools due to its reduction in element distortion problems, prevention of solution termination, an‎d reasonable computational time. Using this model, the stress distribution in tools with different coating thicknesses was analyzed both on the surface an‎d through the depth. The research findings showed that as coating thickness increases, surface stress increases, while the depth of stress effect decreases an‎d becomes closer to the coating surface. To determine the optimal coating thickness, the balance between these two trends was eva‎luated. The effect of friction coefficient was also investigated in three cases (no friction, friction coefficient of 0.1, an‎d 0.2), an‎d a similar trend was observed in all cases.

صالح اكبرزاده , محمد سيلاني

محمد مشايخي , محسن اصفهانيان