The manufacturing process of coated cutting carbide tools is highly specialized and indicated by a complex grinding strategy. Different grinding operations are used with high demands towards homogenous properties of ground surfaces. Properties like roughness, surface topography, and residual stress highly influence the wear behavior of cutting tools and especially of coated cutting tools. Due to complex shaped drilling and milling tools, several grinding operations are used to manufacture the entire tool. The different grinding processes determine different residual stress states in the subsurface of the substrate due to various mechanical and thermal loads. In this contribution the three different grinding operations, cup wheel grinding, creep feed grinding, and peripheral grinding, are investigated. The experimental procedure shows, that the various grinding processes determine different properties of the ground surface like topography, roughness and residual stress. To characterize and compare the various grinding operations, a model for chip thickness in grinding is introduced. The results in experiments show a distinct correlation between the chip thickness in grinding and several properties of the ground surface. As a result of improving the residual stress state of the carbide tool, a superior wear behavior in dry machining is observed.
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