Microstructure-level model for the prediction of tool failure in coated WC-Co cutting tool materials during intermittent cutting

A model to predict failure of coated WC-Co grades due to chipping in intermittent cutting via microstructure-level finite element machining process simulation is presented and applied to various coated WC-Co tools. Coated tools were examined for the characterization and simulation of their microstructures. Model predictions of failure due to chipping for coated WC-Co systems were validated by continuous machining tests. In order to simulate cyclic loading conditions during intermittent cutting, mechanical and thermal boundary conditions were applied during cutting phases and removed during noncutting phases. Interrupted turning experiments were conducted to validate the model and the results showed that the predictions agreed well with the observations from the experiments. The paper includes the application of this model to a problem of WC-Co grade design. [DOI: 10.1115/1.2738507]