Flank Wear of Multi-Layer Coated Tool and Wear Prediction Using Abrasion Wear Model

In this paper, we have combined experimental and numerical approaches to understand the flank wear and its evolution of the multi-layer (TiCN/Al₂O₃/TiCN) coated carbide insert after continuous turning of AISI 1045 steels. In addition using advanced microscope techniques such as scanning electron microscope, confocal laser scanning microscope, etc., we have captured the three dimensional images of flank wear. Using the wavelet filtering, the roughness profiles and groove sizes on the flank surface were analyzed and compared. Both 2-body and 3-body abrasion models were used as the basis to predict flank wear lands, which are then compared with the experimentally observed wear images. Finite Element (FE) models were developed to simulate the changes on the interfacial conditions as the flank wear progresses during cutting.