Numerical simulations of 3D tool geometry effects on deposition residual stresses in diamond coated cutting tools

Deposition residual stresses in diamond-coated cutting tools significantly impact the coating adhesion and machining performance. In this study, Computer-Aided Design (CAD) software was used to create the solid model of coated tools, and further exported to Finite Element Analysis (FEA) software for 3D simulations of residual stresses generated. Design of experiments approach was employed to systematically investigate the tool geometry effects. Major results are summarised as follows. • the cutting edge radius is the most significant factor • for a 5 µm edge radius, the radial and circumferential normal stresses (�1 r and �1 �� ) are about 1.5 GPa in tension and 3.7 GPa in compression, respectively.