Finite element analysis of the effects of theCu:CNx nano-composite multilayer coating onto the improvement of cutting tool life

Abstract: To verify the effects of applying the shim with nanostructured composite damping coating onto the improvement of cutting tool life, the thesis studies two related aspects, the experiment and finite element software simulation. The experiment part mainly discusses the methods of designing the experiment process and verifying the damping vibration effectiveness of the coated shim. It gives a brief introduction to the experiment, including the procedures and the results. During the experiment, the traditional shim and the shim with nanostructured composite damping coating-CuCNx were turned respectively under the condition that the turning process remains the same, and the results were tested and checked by two methods. Firstly, the PSD of acceleration data in cutting tangential direction was recorded in real time by LMS software. Secondly, the flank wear of the tool was observed with optical microscope every 10 minutes. The results showed that the coated shim can effectively reduce the tool vibration and prolong the tool life, which is convincing evidence of the damping effect of nano composite coating. In the simulation part, ABAQUS software was used for the 3D Finite Element Analysis simulation. Instead of applying the common orthogonal cutting simulation model, the research used the real partsize and real machining parameters from the experiment for simulation. In addition, this part also introduces the methods of establishing the finite element model and setting the parameters in the software. The possible error messages and the reasons for the simulation failure would also be listed. Given that the simulation calculation continues to be optimized and completed, the thesis compares the stress levels on the insert with different shim conditions. The stimulation results showed that the stress was decreased with the application of the coating shim on the model of the cutting tool, proving that the composite coating of the shim can effectively expand the tool life. This thesis discusses the feasibility and reliability of using Finite Element Analysis simulation to analyze the cutting process, as well as verifying the effect of the coated shim.