Coating-substrate interface properties and deposition residual stresses may have significant effects on diamond-coated tool performance. However, it is still distant to understand how the interface mechanical behavior and deposition residual stress together influence the diamond-coated tool thermo-mechanical behavior during machining. In this study, a 2D cutting simulation incorporating deposition residual stresses and an interface cohesive zone model has been developed to demonstrate the feasibility of evaluating coating delamination of a diamond-coated tool during cutting.

It has been shown that even the residual deposition stresses alone may result in crack initiations in the cohesive zone (i.e., the interface). In addition, the study further demonstrates that the feasibility of implementing cohesive zone interface in a diamond-coated tool in 2D cutting simulation. An example of cohesive failure occurred in the cutting simulation is shown. The result shows a large uncut chip thickness can cause cohesive delamination during cutting.

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