Three-dimensional numerical simulation of soft/hard composite-coated textured tools in dry turning of AISI 1045 steel

A structural model of a soft/hard composite-coated textured (SHCCT) tool was proposed and substantiated by a three-dimensional numerical simulation. Its dry turning performance as applied to AISI-1045 steel was analyzed via three-factor five-level orthogonal experiments for different coating parameters, including coating thickness, coating material, and thickness ratio of the soft and hard coatings. In addition, the cutting performance of the proposed SHCCT tool was compared with those of uncoated non-textured, coated non-textured, and uncoated textured tools, and its superiority was proved by the significant reductions in the cutting force, and specifically, the cutting temperature. The optimal results were provided by the SHCCT tool with a WS 2 /ZrN soft/hard composite coating, a 0.9:0.1 thickness ratio of the above ingredients, and a total coating thickness of 0.5 μm.