PVD Technology (Tools)


Ongoing projects


Portrait photo Kalscheuer © Copyright: Carl Brunn


Dr. Christian Kalscheuer

Chief Engineer and Team Leader PVD-W


+49 241 80-96512



Development of a Greybox model for wear prognosis of PVD coated carbide tools during high performance turning of steels

Short description:

The main aim of the research project is the development of a Greybox model for an accurate prediction of tool life and remaining service life of PVD coated carbide tools during high-performance turning of steels. For this purpose, analytical Whitebox models for determination of the instationary thermomechanical stresses in the cutting process and experimentally determined machine data, coating properties and tool wear progress will be coupled by means of machine learning based Blackbox models. Firstly, TiAlCrSiN and TiAlCrSiON coatings will be deposited on the cutting inserts and characterized. Subsequently, the temperature dependent elastic-plastic coating properties and the system behavior are to be determined. The coated tools will then be used for rough turning of heat-treated C45 and 42CrMo4 steels. Cutting tests with in situ acquisition of the process state variables and focus on linear to progressive tool wear transition zone will form the experimental basis for quantitative tool damage analysis. Finally, a Greybox model for tool life prediction will be developed and validated.

Funding: German Research Foundation (DFG)
Project number: BO 1979/99-1
Duration: July 1, 2023 to June 30, 2026

Fundamental investigations for the simulative dimensioning and knowledge-based production of PVD-coated cutting tools for turning operations

Short description:

The project aim is the availability of fundamental knowledge about the correlation between coating properties, such as coating morphology, coating thickness, coating hardness and residual stresses, the cutting edge microgeometry and the resulting wear and failure phenomena during continuous and discontinuous turning processes. These findings are used to develop and validate a simulation-based design method for PVD-coated carbide tools with an adapted cutting edge microgeometry. In addition, knowledge about the influence of the coating parameters on the resulting coating, composite and system properties will be generated as part of the basic characterization of the tools. The TiAlSiN coatings are produced in direct current magnetron sputtering (dcMS) / high power pulse magnetron sputtering (HPPMS) coating processes using an industrial coating unit.

Funding: German Research Foundation (DFG)
Project number: BO 1979/82-1
Duration: December 1, 2021 to November 30, 2024

Influence of HPPMS pulse parameters on stoichiometry and the formation of reaction layers on nitridic hard coatings for metal cutting

Short description:

The overall aim of the research period now applied for is to gain knowledge about the influence of the chemical composition of TiAlCrSiON nanocomposites on the interaction with steel under tribological load and on the damage collective in machining. After coating deposition, an influence of the chemical composition on the coating properties is investigated. Moreover, the relationships between the coating properties, the frictional behavior and the formation of reaction layers are investigated in tribological system tests. It is also investigated whether wear can be reduced in the system tests by increasing the aluminium and oxygen content. Finally, it will be investigated whether the correlations found in the system tests can be transferred to field tests. Here, the extent of the fundamental damage mechanisms in the machining process is investigated as a function of the frictional behavior. Poster BO 1979/48-2

Funding: German Research Foundation (DFG)
Project number: BO 1979/48-2
Duration: October 1, 2021 to March 31, 2024