Crack propagation in coated cutting tools during machining: XFEM-CZM computational analysis

This study presents a computational framework to investigate crack initiation, propagation, and interaction in coated cutting tools under machining conditions. A hybrid approach combining the extended finite element method (XFEM) and the cohesive zone method (CZM) is employed to simultaneously model bulk crack evolution and interfacial debonding. A systematic parametric study assesses the influence of crack orientation, position, origin, length, and inter-crack distance on propagation behavior. Results highlight the critical role of crack orientation and interface proximity in governing crack paths and interaction mechanisms. The proposed framework provides new insights into multi-crack evolution and offers a predictive tool for improving coating design and tool durability under severe mechanical loading conditions associated with machining.