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Toollifeofthecoatingsininterruptedcutof42CrMo4123 154Prod.Eng.Res.Devel.(2016)10:147–155coating groupABCDE25distance fromdistance fromsurface0minsurface015105composition ofthe coatings(material-0composition ofthe coatings(chemical wearresistance)tool life critera:tc = 20 min, VB > 200 µm, tool failure due to chippingdepending)process:tool:external turningCNMG 120412 MSworkpiece: Ti-6Al-4Vinterruptedprocess parameters:vc = 60 m/mindistance fromsurface0high hardnessf = 0.1 mmof the coatings(stable craterlip)cut:ap = 1 mmRi/79926 ©IFWFig.11 ToollifeofthecoatingsininterruptedcutofTi–6Al–4Vcomposition and hardness of the coatings limit the cor-relation of these coating properties with every occurredwear form. Therefore, the coatings were partitioned ingroups with similar composition to identify process-specific coating systems fordifferent applications. Itwasshown that the near surface and near substrate residualcoating stresses correlate with the wear behavior, butstrongly depend on the type of wear. Depending on thewear form the coating residual stress depth distributionand its level near the surface and near the substrate caninfluence tool life significantly. The main conclusions ofthis investigation are:compositionsubstratesurface•Decreasing compressive residual stresses from thesurface to the substrate increase the resistance againstflank wear in continuous cut. A compressive residualstress state at the surface of the coating of about-1500MPaexhibitsthehighestperformance.Self-lubricating compositions and low compressiveresidual stresses decreasing to the substrate increasetheresistanceagainstflankwearincontinuouscuttingofTi–6Al–4V.craterwearflankwearchippingRi/79929 ©IFWFig.12 Influenceofcoatingpropertiesonwearbehavior•Thepotentialofthecomposition,residualstressesnearcoating surface and residual stresses near the substrate toincreasetheresistanceagainstcraterwear,flankwearandchippingaresummarizedinFig.12.••••Increasing compressive residual stresses from thesurface of the coating to the substrate increase thestabilityofthecraterlipininterruptedcutof42CrMo4.High compressive stresses near the substrate stabilizethe crater lip and thus reduce chipping at the cuttingedge.AcknowledgmentsThe authors would like to thank the GermanResearchFoundationforthefinancialsupportforthisworkwithintheproject ‘‘Applikationsspezifisches Design von PVD-Beschichtungenfu¨r Zerspanwerkzeuge’’(BR2967/5-1).Material-depending oxide or nitride coatings decreasecraterwearsignificantly,whichisindependentfromtheresidualstressstate.ReferencesInfluence of the subordinately considered layer struc-ture on the wear behavior has to be investigated infurtherstudies.1. 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