Performance and wear mechanisms of uncoated, TiAlN, and AlTiN-coated carbide tools in high-speed drilling of Al-Si alloy

2021 ◽  
Author(s):  
Ali Akhavan Farid ◽  
Safian Sharif ◽  
Mohd Hasbullah Idris
Keyword(s):  
Wear Mechanisms ◽  
High Speed ◽  
High Speed Drilling ◽  
Coated Carbide ◽  
Coated Carbide Tools

Wear Mechanism Analysis of Coated Carbide Tools in High-Speed Milling of Ti-6Al-4V Alloy via Cross-Section Characterization of Worn Cutting Edge

2015 ◽  
Author(s):  
Anhai Li ◽  
Jun Zhao ◽  
Fenghua Lin
Keyword(s):  
Cross Section ◽  
Wear Mechanisms ◽  
High Speed ◽  
Tool Material ◽  
Cutting Edge ◽  
High Speed Machining ◽  
Erosion Wear ◽  
Coated Carbide ◽  
Coated Carbide Tools

Tool wear analysis is essential in high speed machining, especially in the intermittent cutting and milling processes. Analyses of tool wear mechanisms will be beneficial for proposing the suggestions in the tool design process how to enhance the tool material properties to improve the cutting performance and eventually tool life. Wear mechanisms of coated carbide tools in high-speed dry milling of Ti-6A1-4V were assessed by characterization of the cross-section of worn tool cutting edge utilizing scanning electron microscopy, and the element distribution of the worn tool surface was detected by using energy dispersive spectroscopy. Results show that flank wear, chipping and flaking of tool material on the rake face and/or at the nose of tools were the dominant failure modes. And synergistic interaction among coating delamination, erosion wear, adhesion, dissolution-diffusion wear, and thermal-mechanical fatigue wear were the main wear mechanisms analyzed from cross-sectional worn cutting edge. Erosion wear was identified in high speed milling of Titanium alloy and introduced into the wear mechanisms of metal cutting tools. The hydromechanics characteristic of the chips produced in high-speed machining should be responsible for erosion wear of cuttings tools.

Wear mechanisms of micro-drills during dry high speed drilling of PCB

2012 ◽  
Vol 212 (10) ◽  
pp. 1989-1997 ◽  
Author(s):  
L.J. Zheng ◽  
C.Y. Wang ◽  
L.Y. Fu ◽  
L.P. Yang ◽  
Y.P. Qu ◽  
...  
Keyword(s):  
Wear Mechanisms ◽  
High Speed ◽  
High Speed Drilling

Wear and breakage of TiAlN- and TiSiN-coated carbide tools during high-speed milling of hardened steel

Wear ◽  
2015 ◽  
Vol 336-337 ◽  
pp. 29-42 ◽  
Author(s):  
C.Y. Wang ◽  
Y.X. Xie ◽  
Z. Qin ◽  
H.S. Lin ◽  
Y.H. Yuan ◽  
...  
Keyword(s):  
High Speed ◽  
Hardened Steel ◽  
High Speed Milling ◽  
Coated Carbide ◽  
Coated Carbide Tools

Effect of Machining Parameters and MQL Liquids on Surface Integrity of High Speed Drilling Ti-6Al-4V

2010 ◽  
Vol 447-448 ◽  
pp. 816-820 ◽  
Author(s):  
Erween Abdul Rahim ◽  
Hiroyuki Sasahara
Keyword(s):  
Surface Roughness ◽  
Palm Oil ◽  
Surface Integrity ◽  
High Speed ◽  
Cutting Speed ◽  
Machining Parameters ◽  
Machined Surface ◽  
Subsurface Deformation ◽  
High Speed Drilling ◽  
Coated Carbide

Surface integrity is particularly important for the aerospace industry components in order to permit longer service life and maximized its reliability. This present work compares the performance of palm oil and synthetic ester on surface roughness, surface defect, microhardness and subsurface deformation when high speed drilling of Ti-6Al-4V under MQL condition. The drilling tests were conducted with AlTiN coated carbide tool. The surface roughness decreased with increasing in cutting speed and thicker subsurface deformation was formed underneath the machined surface. Grooves, cavities, pit holes, microcracks and material smearing were the dominant surface damages thus deteriorated the machined surface. For both lubricants, the machined surface experienced from thermal softening and work hardening effect thus gave a variation in microhardness values. The results indicated the substantial benefit of MQL by palm oil on surface integrity.

Wear mechanisms of coated carbide tools

1982 ◽  
Vol 9 (1) ◽  
pp. 60-75 ◽  
Author(s):  
P. A. Dearnley ◽  
E. M. Trent
Keyword(s):  
Wear Mechanisms ◽  
Coated Carbide ◽  
Coated Carbide Tools

Microstructure Induced Wear Mechanisms of PVD-Coated Carbide Tools during Dry Drilling of Newly Produced ADI

2015 ◽  
Vol 651-653 ◽  
pp. 1271-1276 ◽  
Author(s):  
Anil Meena ◽  
Mohamed El Mansori
Keyword(s):  
Wear Mechanisms ◽  
Cutting Tools ◽  
Experimental Studies ◽  
Cutting Speed ◽  
Microstructural Characteristics ◽  
Machine Material ◽  
Dry Drilling ◽  
Wear Mode ◽  
Coated Carbide ◽  
Coated Carbide Tools

Near-net shape austempered ductile iron (ADI) castings can be considered as a significant economic advantage to the increasing industrial demand for cost and weight efficient materials. However, due to microstructure induced inherent properties, ADI is considered as hard to machine material. The present paper thus investigates the interaction between the microstructural characteristics of ADI and wear mechanisms of PVD-coated carbide tools. The inherent properties of ADI materials are the function of its microstructural characteristics (retained austenite volume content and its carbon content, ferritic cell size, etc.) which can be controlled by the austempering parameters. Experimental studies of dry drilling of different ADI materials with the PVD-coated carbide tools were carried out at a cutting speed of 60 m/min and at a feed of 0.15 mm/rev. The wear mechanisms of the cutting tools were studied by using scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS) analysis techniques. The obtain results revealed the evolution of crater wear as the main wear mode. In addition, it provides the key findings aims to correlating the machining characteristics of ADI with its microstructure and production conditions.

Wear and cutting forces in high-speed machining of H13 using physical vapour deposition coated carbide tools

2005 ◽  
Vol 219 (2) ◽  
pp. 191-199 ◽  
Author(s):  
P T Mativenga ◽  
K K B Hon
Keyword(s):  
Cutting Forces ◽  
High Speed ◽  
Vapour Deposition ◽  
High Speed Machining ◽  
Physical Vapour Deposition ◽  
Tin Coatings ◽  
Tool Coatings ◽  
Process Trends ◽  
Coated Carbide ◽  
Coated Carbide Tools

This paper reviews the contributions that coatings make in enhancing the cutting performance of carbide tools and, in particular, their application in high-speed machining. It examines flank wear and cutting force process trends that are essential for monitoring tool degradation in automated machining factories. The findings of the investigation into cutting forces over the life cycle of different physical vapour deposition (PVD) tool coatings on micrograin carbide in the high-speed machining of tool steel are presented and related to the existing literature. Cutting tests were carried out at a very high spindle speed, 40000 r/min, and for a predetermined cutting time. Variants of the TiAlN coating, i.e. single- and double-layer and composite coating enhanced with WC/C, were evaluated against the uncoated tool and the TiCN, CrN, and TiN coatings. The paper reflects on the performance of advanced PVD coatings and also presents force trends and suggestions for process monitoring.

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