TiAlN coated carbide tools prepared by arc ion deposition (AIP) can be applied to high-speed, full-dry and semi-dry cutting due to their high thermal oxidation resistance and high wear resistance and low friction coefficient, which can greatly increase productivity. To improve the adhesion strength of TiAlN films, a TiAl intermediate layer was introduced between the substrate and the TiAlNcoating, and the effect of the thickness of the intermediate layer on the adhesion strength of TiAlN films was simulated and experimentally verified. Three-dimensional models of TiAlN coated tools were developed to reflect the actual operating conditions and the simulation on the stresses occurred in the intermediate layer under bending loads and thermal loads was carried out through the finite element analysis software ANSYS 19.0. The whole model was constructed for different intermediate layer thicknesses, respectively, and the stresses and strains generated in the intermediate layer were analyzed through simulations. The stress distribution values obtained from the simulation results were compared with the experimental adhesion strength results and the relationship between the stress occurred in the intermediate layer and the adhesion strength was analyzed. The maximum adhesion strength of the coating was 42.7 N for interlayer thickness of W = 0.8㎛, while the bending stress occurring in the considered region at different load conditions (mechanical and thermal loading) was 24.7 MPa, thermal stress 390 GPa and thermal strain 460㎛ were minimized
