Effects of Edge Radius and Coating Thickness on the Cutting Performance of AlCrN-Coated Tool

High-speed machining is a practical way to attain high productivity with lower costs. Under this condition, the tool geometry needs to be optimized to sustain high cutting forces and temperatures. The sharpness of the cutting edge and the coating thickness (CT) are two key parameters that affect the tool’s performance. While a sharp edge eases the cutting process, it causes a high stress concentration, which increases the wear rate and eventual edge fracture. In this study, we use a combination of finite element simulations and experimental testing to evaluate the effects of CT ( 1–3 μm), edge radius (rβ$$r_{\beta }$$ , 6–15 μm), and coefficient of friction (μ=0-0.2$$\upmu = 0 - 0.2$$) on the stress distribution at the cutting edge. Our simulations showed that the larger the CT, the higher the stress magnitude inside the coating, but the lower the maximum stress depth percentile. Considering an industrial case of cutting steel workpieces using AlCrN-coated tungsten carbide tools under given cutting parameters, our simulations suggested an optimum CT of 3 μm. By manufacturing a series of milling tools with different CTs and edge radii, we validated the simulation results using a set of well-controlled milling experiments. Finally, the edge radius should be selected considering the size of rake/flank angle mainly to control stress distribution over the cutting edge.