Prediction of cutting speed interval of diamond-coated tools with residual stress

Abstract

This article deals with finite element (FE) analysis incorporating deposition stress effects to determine the optimal cutting speed interval, V-interval, and evaluate the effects of cutting speed on the interface behavior of diamond-coated tools in machining of AA356-T6 aluminum alloy. A model for predicting the V-interval limited through the lower, V-lower, and upper, V-upper, cutting speeds is also presented. The results show that the deposition process causes high residual stress around the round edge on the coating side. When machining load corresponding to the speed interval is applied, the residual stress on the coating side is decreased at the V-upper.