Experimental and theoretical analysis of tool life between plasma enhanced CVD and PVD multilayer nanocoated cutting tools

The article includes research results for the functional properties achieved for a wide range of sintered tool materials, including sintered carbides, cermets and three types of Al2O3 oxide tool ceramics ((Al2O3 + ZrO2, Al2O3 + TiC and Al2O3 + SiC(w)) with (Ti,Al)N coating deposited in the cathodic arc evaporation (CAE-PVD) method and comparison with uncoated tool materials. For all coated samples, a uniform wear pattern on tool shank was observed during metallographic analysis. Based on the scanning electron microscope (SEM) metallographic analysis, it was found that the most common types of tribological defects identified in tested materials are: mechanical defects and abrasive wear of the tool side, crater formation on the tool face, cracks on the tool side, chipping on the cutting edge and built-up edge from chip fragments. Deposition of (Ti,Al)N coating on all tested substrates increases the wear resistance and also limits the exceeding of critical levels of permanent stresses. It even increases the tool life many times over. Such a significant increase in tool life results, among other things, from a large increase in microhardness of PVD coated materials compared to uncoated samples, increased resistance to thermal and chemical abrasion, improved chip formation and removal process conditions. Use of hard coatings applied to sintered tool materials is considered to be one of the most important achievements in improving the functional properties of cutting tools and can still be developed by improving the coating structure solutions (sorted and nanocrystalline structures) and extending the range of coating applications (Ti,Al)N in a variety of substrates.

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Kantenpräparation durch Formschleifprozesse*/Cutting edge preparation by form grinding

wt Werkstattstechnik online ◽

10.37544/1436-4980-2017-06-69 ◽

2017 ◽

Vol 107 (06) ◽

pp. 453-460

Author(s):

E. Prof. Uhlmann ◽

J. Bruckhoff

Keyword(s):

Tool Life ◽

Cutting Tools ◽

Cutting Edge ◽

Grinding Processes ◽

Form Grinding ◽

Cutting Edge Preparation ◽

Edge Preparation

Angesichts steigender Anforderungen an Zerspanwerkzeuge nimmt die Schneidkantenpräparation einen immer größer werdenden Stellenwert ein, da sich so die Standzeit von Zerspanwerkzeugen erhöhen lässt. Die bisher eingesetzten Präparationsverfahren eignen sich meist nur für einfache Verrundungen an der Schneidkante. In umfangreichen Untersuchungen wurde die Eignung von Formschleifprozessen zur Herstellung definierter Schneidkantenmikrogeometrien anhand von Arbeitsergebnissen analysiert.   Due to increasing demands on cutting tools cutting edge preparation has a high priority because it influences the tool life. Current cutting edge preparation processes can only generate simple roundings on the cutting edge. By extensive investigations the suitability of form grinding processes for the production of defined microgeometries on the cutting edge was analysed.

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Tribological properties of ion-modified composite coatings

Journal of Physics Conference Series ◽

10.1088/1742-6596/2059/1/012015 ◽

2021 ◽

Vol 2059 (1) ◽

pp. 012015

Author(s):

M Sh Migranov ◽

A M Migranov ◽

S R Shekhtman

Keyword(s):

Wear Resistance ◽

Tool Life ◽

High Speed ◽

Composite Coatings ◽

Cutting Tools ◽

High Speed Steel ◽

Hard Coating ◽

Ion Nitriding ◽

Additional Layer ◽

Nitrided Surface

Abstract The paper presents the results of a study of one of the ways to increase the wear resistance of “duplex” coatings applied to cutting tools, which are due to preliminary diffusion saturation of the tool surface with nitrogen (known as ion nitriding) followed by physical deposition of a hard coating (Ti, Cr) N. The proposed coating also contains an additional layer with an impurity of ions, deposited on a preliminary nitrided surface of high speed steel before the deposition of a hard coating. Tests were carried out to evaluate the effect of these modified layers on the tool life of the HSS tool. The greatest wear resistance after "triplex" - treatment was achieved during ion implantation of titanium into a pre-nitrided surface. The coefficient of friction of the modified layer was studied at different contact temperatures. Ionic mixing contributes to the appearance of a thin surface layer with an amorphous-like structure, which prolongs the stage of normal wear, which significantly increases the tool life as a result of the self-organization process.

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The design of bottomhole assembly with two rock cutting tools for directional drilling

Prospecting and Development of Oil and Gas Fields ◽

10.31471/1993-9973-2018-2(67)-14-20 ◽

2018 ◽

pp. 14-20

Author(s):

I. V. Voievidko ◽

V. V. Tokaruk ◽

M. A. Bodzian

Keyword(s):

Theoretical Analysis ◽

Inclination Angle ◽

Large Diameter ◽

Cutting Tools ◽

Intensity Variation ◽

Rock Cutting ◽

Hole Drilling ◽

Directional Drilling ◽

Geological Conditions ◽

Technical Factors

On the basis of the theoretical analysis and practical studies of hole drilling of large diameter, a method for designing the BHA with two rock cutting tools is proposed, taking into account the geological and technical factors that have an impact on the formation of the trajectory. The calculation of BHA with two rock cutting tools and a different number of supporting and centralizing components for different geological conditions of drilling is carried out and the analysis of their work in the process of drilling is conducted. The graphic dependences of the deviation intensity variation and the inclination angle with the sinking of borehole of the large diameter for the BHA that can be used for the drilling of vertical and directional wells.

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Development of Cutting Tools With Micro-Textured Surface for High Speed Machining of Ti-6Al-4V

Volume 1: Additive Manufacturing; Advanced Materials Manufacturing; Biomanufacturing; Life Cycle Engineering; Manufacturing Equipment and Automation ◽

10.1115/msec2021-63373 ◽

2021 ◽

Author(s):

Mitsuru Hasegawa ◽

Tatsuya Sugihara

Keyword(s):

Tool Life ◽

High Speed ◽

Metal Cutting ◽

Failure Process ◽

Cutting Tools ◽

Cutting Temperature ◽

Cutting Speed ◽

Cutting Fluid ◽

Textured Surface ◽

Textured Surfaces

Abstract In cutting of Ti-6Al-4V alloy, the cutting speed is limited since a high cutting temperature leads to severe tool wear and short tool life, resulting in poor production efficiency. On the other hand, some recent literature has reported that various beneficial effects can be provided by forming micro-textures on the tool surface in the metal cutting process. In this study, in order to achieve high-performance machining of Ti-6Al-4V, we first investigated the mechanism of the tool failure process for a cemented carbide cutting tool in high-speed turning of Ti-6Al-4V. Based on the results, cutting tools with micro textured surfaces were developed under the consideration of a cutting fluid action. A series of experiments showed that the textured rake face successfully decreases the cutting temperature, resulting in a significant suppression of both crater wear and flank wear. In addition, the temperature zone where the texture tool is effective in terms of the tool life in the Ti-6Al-4V cutting was discussed.

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Investigation into Performance of Multilayer Composite Nano-Structured Cr-CrN-(Cr0.35Ti0.40Al0.25)N Coating for Metal Cutting Tools

Coatings ◽

10.3390/coatings8120447 ◽

2018 ◽

Vol 8 (12) ◽

pp. 447 ◽

Cited By ~ 3

Author(s):

Sergey Grigoriev ◽

Alexey Vereschaka ◽

Alexander Metel ◽

Nikolay Sitnikov ◽

Filipp Milovich ◽

...

Keyword(s):

Tool Life ◽

Metal Cutting ◽

Cutting Tools ◽

Cutting Speed ◽

Constructional Steel ◽

Wear Process ◽

Layered Architecture ◽

Process Pattern ◽

Resistant Layer ◽

Cutting Speeds

This paper deals with the Cr-CrN-(Cr0.35Ti0.40Al0.25)N coating. It has a three-layered architecture with a nano-structured wear-resistant layer. The studies involved the investigation into the microstructure (with the use of SEM and TEM), elemental and phase composition (XRD and SAED patterns), wear process pattern in scratch testing, crystal structure, as well as the microhardness of the coating. Cutting tests of tools with the above coating were carried out in dry turning of steel 1045 at cutting speeds of vc = 200, 250, and 300 m·min−1. The comparison included uncoated tools and tools with the commercial TiN and (Ti,Al)N coatings with the same thickness. The tool with the Cr-CrN-(Cr0.35Ti0.40Al0.25)N coating showed the longest tool life at all the cutting speeds under consideration. Meanwhile, a tool with the coating under study can be recommended for use in turning constructional steel at the cutting speed of vc = 250 m·min−1. At this cutting speed, a tool shows the combination of a rather long tool life and balanced wear process, without any threat of catastrophic wear.

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Comparative Experimental Research on Cutting Superalloy Used New Coated Carbide Tools

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.33.173 ◽

2010 ◽

Vol 33 ◽

pp. 173-176

Author(s):

X.Y. Wang ◽

S.Q. Pang ◽

Q.X. Yu

Keyword(s):

Tool Wear ◽

Tool Life ◽

Experimental Research ◽

Cutting Tools ◽

Cutting Speed ◽

Life Testing ◽

Processing Efficiency ◽

Comparative Tests ◽

Coated Carbide ◽

Coated Carbide Tools

The aim of this work is to investigate the machinability of new coated carbide cutting tools that are named C7 plus coatings under turning of superalloy GH2132. This achieved by analysis of tool life at different cutting conditions .Investigations of tool wear and tool life testing are intended to establish T-V formulas, and then analyzed the characteristics of coating . Through a series of comparative tests, Using TiAlN coatings as the contrast materialthe results show that the new coating tools that are named C7 plus coatings are suitable for cutting superalloy GH2132. The cutting speed and processing efficiency can be increased effectively.

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A novel treatment for cutting tools for reducing the chipping and improving tool life during machining of Inconel 718

Wear ◽

10.1016/j.wear.2018.08.002 ◽

2018 ◽

Vol 414-415 ◽

pp. 79-88 ◽

Cited By ~ 12

Author(s):

Maryam Aramesh ◽

Saharnaz Montazeri ◽

Stephen C. Veldhuis

Keyword(s):

Tool Life ◽

Inconel 718 ◽

Cutting Tools ◽

Novel Treatment

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DLC and DLC-WS2 Coatings for Machining of Aluminium Alloys

Coatings ◽

10.3390/coatings9030192 ◽

2019 ◽

Vol 9 (3) ◽

pp. 192 ◽

Cited By ~ 3

Author(s):

Tomasz Brzezinka ◽

Jeff Rao ◽

Jose Paiva ◽

Joern Kohlscheen ◽

German Fox-Rabinovich ◽

...

Keyword(s):

Wear Rate ◽

Tool Life ◽

Physical Vapor Deposition ◽

Methodological Approach ◽

Cutting Tools ◽

Vacuum Arc ◽

Limiting Factor ◽

Dlc Coating ◽

Operational Life ◽

Filtered Cathodic Vacuum Arc

Machine-tool life is one limiting factor affecting productivity. The requirement for wear-resistant materials for cutting tools to increase their longevity is therefore critical. Titanium diboride (TiB2) coated cutting tools have been successfully employed for machining of AlSi alloys widely used in the automotive industry. This paper presents a methodological approach to improving the self-lubricating properties within the cutting zone of a tungsten carbide milling insert precoated with TiB2, thereby increasing the operational life of the tool. A unique hybrid Physical Vapor Deposition (PVD) system was used in this study, allowing diamond-like carbon (DLC) to be deposited by filtered cathodic vacuum arc (FCVA) while PVD magnetron sputtering was employed to deposit WS2. A series of ~100-nm monolayer DLC coatings were prepared at a negative bias voltage ranging between −50 and −200 V, along with multilayered DLC-WS2 coatings (total thickness ~500 nm) with varying number of layers (two to 24 in total). The wear rate of the coated milling inserts was investigated by measuring the flank wear during face milling of an Al-10Si. It was ascertained that employing monolayer DLC coating reduced the coated tool wear rate by ~85% compared to a TiB2 benchmark. Combining DLC with WS2 as a multilayered coating further improved tool life. The best tribological properties were found for a two-layer DLC-WS2 coating which decreased wear rate by ~75% compared to TiB2, with a measured coefficient of friction of 0.05.

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