Wear Mechanisms of Multi-Layer Coated Cemented Carbide Cutting Tools

1997 ◽  
Vol 119 (1) ◽  
pp. 8-17 ◽  
Author(s):  
S.-S. Cho ◽  
K. Komvopoulos
Keyword(s):  
Tool Wear ◽  
Wear Mechanisms ◽  
Wear Behavior ◽  
Cutting Tools ◽  
Tool Material ◽  
Surface Plastic ◽  
Delamination Wear ◽  
Interfacial Cracks ◽  
Plastic Shearing ◽  
Coated Cemented Carbide

Turning experiments were performed with cemented WC-Co cutting tools coated with two-layer and three-layer overcoats of TiC/Al2O3 and TiC/Al2O3/TiN, respectively. For comparison, uncoated WC-Co tools were also tested under similar cutting conditions. The predominant wear mechanisms of the various ceramic overcoats and cemented WC-Co were investigated using surface profilometry, scanning electron microscopy, and energy dispersive X-ray analysis. Representative results of the tool wear behavior are presented, and the significance of each ceramic layer on the overall tool wear resistance is interpreted in light of the identified dominant wear mechanisms. Delamination wear characterized by the propagation and linkage of surface, subsurface, and interfacial cracks, abrasion, surface plastic shearing, plucking of carbide grains, and dissolution/diffusion are shown to occur depending on the tool material. These wear processes are not mutually exclusive; they may occur simultaneously at different positions on the same tool surface. Based on nose wear data, correlations between wear lives of coated and uncoated tools and feedrate are established.

scholarly journals Machining of Iron-Carbon Alloys by the Use of Poly-Crystalline Diamond Cutting Inserts with Internal Cooling

2018 ◽  
Vol 2 (3) ◽  
pp. 57 ◽  
Author(s):  
Manuel Reiter ◽  
Jens Brier ◽  
Friedrich Bleicher
Keyword(s):  
Wear Behavior ◽  
Cutting Tools ◽  
Tool Material ◽  
Internal Cooling ◽  
Diamond Cutting ◽  
Diffusion Effects ◽  
Cutting Inserts ◽  
Abrasive Cutting ◽  
Poly Crystalline Diamond ◽  
Insight Into

Poly-crystalline diamond (PCD) is an extremely tough, synthetically produced cutting tool material, which offers outstanding capabilities concerning wear behavior in abrasive cutting environments. Currently, the primary application of PCD cutting tools is the machining of non-ferrous materials, as the diamond’s carbon high affinity towards iron causes diffusion effects while cutting steel with rising temperature. This effect significantly reduces tool life. To lower the occurring temperature of the cutting process, and therefore avoid the reaction of carbon and iron, a thermal functionalization of the cutting inserts has been investigated. The results give insight into making PCD cutting tools economically usable for the machining of iron-carbon materials.

Experimental Study on Tool Wear when Machining Super Titanium Alloys: Ti6Al4V and Ti-555

2013 ◽  
Vol 763 ◽  
pp. 51-64
Author(s):  
Mohammed Nouari ◽  
Hamid Makich
Keyword(s):  
Tool Wear ◽  
Temperature Rise ◽  
Wear Behavior ◽  
Flow Direction ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Wear Process ◽  
Texture Modification ◽  
Wear Modes

To understand the effect of the workpiece microstructure on the tool wear behavior, anexperimental investigation was conducted on machining two different microstructures of supertitanium alloys: Ti-6Al-4V and Ti-555. The analysis of tool-chip interface parameters such asfriction, heat flux and temperature rise and the evolution of the workpiece microstructure underdifferent cutting conditions have been discussed. As cutting speed and feed rate increase, the meancutting forces and temperature show different progressions depending on the consideredmicrostructure. Results show that wear modes for cutting tools used in machining the Ti-555 alloyshow contrast from those exhibited by tools used in machining the Ti6AI4V alloy. In fact, onlyabrasion wear was observed for cutting tools in the case of machining the near-β titanium Ti-555alloy. The last alloy is characterized by a fine-sized microstructure (order of 1 μm). For the usualTi6Al4V alloy, adhesion and diffusion modes followed by coating delamination process on the toolsubstrate have been clearly identified. Moreover, a deformed layer was observed under secondaryelectron microscope (SEM) from the sub-surface of the chip with β-grains orientation along thechip flow direction. The analysis of the microstructure confirms the intense deformation of themachined surface and shows a texture modification, without phase transformation. For the Ti-555β-alloy, β grains experiences more plastic deformation and increases the microhardness of theworkpiece inducing then an abrasion wear process for cemented carbide tools. For the Ti6Al4Vmicrostructure, the temperature rise induces a thermal softening process of the workpiece andgenerates adhesive wear modes for cutting tools. The observed worn tool surfaces confirm theeffect of the microstructure on tool wear under different cutting conditions for the two studiedtitanium alloys.

Study on Tool Life and Tool Wear Mechanisms in Dry Cutting Pure Iron

2013 ◽  
Vol 770 ◽  
pp. 74-77 ◽  
Author(s):  
Jin Xing Kong ◽  
Liang Li ◽  
Dong Ming Xu ◽  
Ning He
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Wear Mechanisms ◽  
Pure Iron ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Cutting Condition ◽  
High Plasticity ◽  
Dry Cutting ◽  
Tool Wear Mechanisms

Pure iron is a kind of high plasticity and toughness material. In the process of cutting pure iron, the tool wear is very serious. In this paper, three kinds of cutting tools KC5010, K313 and 1105 are used in the cutting pure iron process and the tool wear tests in dry cutting condition with different cutting parameters have been carried out. According to the results, the tool wear mechanisms and tool life of three kinds of cutting tools have been compared and analyzed. It is concluded that the tool life of K313 is better than KC5010 and 1105 and the three kinds of tool mechanisms are primarily adhesion wear, diffusion wear and oxidation wear.

Tool Wear Behavior in Turning Inconel 718 with Coated Inserts

2012 ◽  
Vol 499 ◽  
pp. 348-352 ◽  
Author(s):  
Xiao Li Zhu ◽  
Song Zhang ◽  
X.L. Xu ◽  
H.G. Lv
Keyword(s):  
Tool Wear ◽  
Inconel 718 ◽  
Flank Wear ◽  
Wear Behavior ◽  
Cutting Tools ◽  
Three Dimensional ◽  
Cutting Condition ◽  
Tool Holder ◽  
Final Failure ◽  
Coated Carbide

In the present study, an experimental investigation has been carried out in an attempt to monitor tool wear progress in turning Inconel 718 with coated carbide inserts under the wet cutting condition. First, each experimental test was conducted with a new cutting edge and the turning process was stopped at a certain interval of time. Secondly, the indexable insert was removed from the tool holder and the flank wear of the insert was measured using a three-dimensional digital microscopy (VHX-600E); and then the insert was clamped into the tool holder for the next turning experiment. The final failure of tool wear surfaces were examined under a scanning electron microscope (SEM) equipped with an energy dispersive X-ray spectrometer (EDS). It is indicated that significant flank wear was the predominant failure mode, and the abrasive, adhesive and oxidation wear were the most dominant wear mechanisms which directly control the deterioration and final failure of the cutting tools.

Analysis of Tool Wear—Part I: Theoretical Models of Flank Wear

1969 ◽  
Vol 91 (3) ◽  
pp. 790-796 ◽  
Author(s):  
A. Bhattacharyya ◽  
I. Ham
Keyword(s):  
Tool Wear ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Tools ◽  
Tool Material ◽  
High Strength ◽  
Theoretical Models ◽  
Flank Surface ◽  
Form Stability ◽  
Sufficient Strength

Cutting tools of sufficient strength against failure by brittle fracture or loss of “form stability” through rise of interface temperatures, still continue to fail by a process of “wear,” which is loss of cutting tool material through gradual interaction between the work and the tool material. Such wear can take place either at the principal flank surface or at the top face of the cutting tool for roughing and semiroughing cuts. Wear may also occur at the auxiliary flank surface resulting in grooving wear during fine machining or machining of high strength materials. The causes for such wear processes include (i) mechanical interaction (abrasion or adhesion and transfer type), (ii) thermochemical interaction (diffusion or chemical reaction). As a part of this investigation on tool wear, two theoretical models have been proposed for explaining mechanical wear at the flank surface. These models explain the nature and characteristics of wear growth and the sensitiveness and dependence of interaction phenomena between the tool-work pair.

Wear Mechanisms of PCBN Cutting Tools in Hard and Dry Cutting GCr15 Bearing Steel

2011 ◽  
Vol 197-198 ◽  
pp. 1494-1499
Author(s):  
Rui Ping Liu ◽  
Fu Ming Deng ◽  
Xue Jun Lu
Keyword(s):  
Phase Transition ◽  
Tool Wear ◽  
Wear Mechanisms ◽  
Joint Action ◽  
Cutting Tools ◽  
Bearing Steel ◽  
Element Distribution ◽  
Dry Cutting ◽  
Gcr15 Bearing Steel ◽  
Flank Face

GCr15 bearing steel was turned with PCBN cutting tools in a manner of hard and dry cutting, and the characteristics and morphology of rake and flank face of PCBN cutting tools were observed, the element distribution of different regions of rake and flank face of PCBN cutting tools were tested and analyzed by use of EDS, and finally the wear mechanisms of PCBN cutting tools were discussed. The results showed that the wear areas of rake and flank face of PCBN cutting tools were small and mostly concentrated near the tip and sub-chamfering, and the reason was mechanical, oxidation, chemical and phase transition wear, which resulted in the joint action of tool wear.

Research of Technology of Cutting Hardened Steel in HSM

2011 ◽  
Vol 338 ◽  
pp. 701-705
Author(s):  
Xiao Jun Zhu ◽  
Wen Sheng Xia
Keyword(s):  
High Speed ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Tool Material ◽  
Main Tool ◽  
Hardened Steel ◽  
Detection Methods ◽  
Tool Geometry ◽  
High Speed Milling ◽  
Coated Cemented Carbide

The key technology of the cutter that cutting hardened steel was researched by high speed milling machining method. At first ,three cutting elements of high speed milling machining was narratived, and we can obtain the principle of selection of parameters of cutting velocity, feed per tooth, longitudinal cutting depth and cutting width of axial, etc. With HSM ,we discussed the performance and selection points of tool material of coated cemented carbide, ceramic, cubic boron nitride , synthetic diamond and so on, and obtained the effect of the main tool geometry for the cutting process in HSM. The second, it analysised type and reason of damage of high speed cutting tools, and introduced three detection methods of tools. Finally, it was summarized and concluded.

Application of CBN Cutting Tools in Hard Turning and Tool Wear

2013 ◽  
Vol 690-693 ◽  
pp. 2022-2025
Author(s):  
Hai Dong Zhao ◽  
Li Bao An ◽  
Pei Qing Yang ◽  
Ye Geng
Keyword(s):  
Tool Wear ◽  
Hard Turning ◽  
Manufacturing Industry ◽  
Metal Cutting ◽  
Elevated Temperatures ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Tool Material ◽  
Specific Strength ◽  
Strength And Stiffness

Considerable research has been directed towards discovering new engineering materials for various applications. As a superhard material, Cubic Boron Nitride (CBN) has been developed and applied to engineering for several tens of years. Due to its high specific strength and stiffness as well as good creep, fatigue and wear resistance at elevated temperatures, CBN has been widely used as cutting tool material in manufacturing industry. In this paper, the preparation and characteristics of CBN are introduced. As hard turning has been more and more employed in recent years as an advanced metal cutting technique, the application of CBN cutting tools in hard turning is presented based on the literature, and in particular, the main wear mechanisms of CBN tools in hard turning are summarized, owing to the significant influence of tool wear on the tool life and product quality.

Effect of Subsurface Deformation on Sliding Wear Behavior of Ti-29Nb-13Ta-4.6Zr Alloys for Biomedical Applications

2014 ◽  
Vol 616 ◽  
pp. 270-274
Author(s):  
Yoon Seok Lee ◽  
Mitsuo Niinomi ◽  
Masaaki Nakai ◽  
Kengo Narita ◽  
Junko Hieda ◽  
...  
Keyword(s):  
Wear Mechanisms ◽  
Wear Behavior ◽  
Testing Machine ◽  
Wear Test ◽  
Wear Testing ◽  
Wear Properties ◽  
Delamination Wear ◽  
Frictional Wear ◽  
Fixation Devices ◽  
Spinal Fixation Devices

The wear mechanisms of conventional Ti–6Al–4V extra-low interstitial (Ti64) and the new Ti–29Nb–13Ta–4.6Zr (TNTZ) were studied to investigate the wear properties of Ti64/TNTZ for application in spinal fixation devices. Ti64 and TNTZ balls and discs were first prepared as wear-test specimens. A ball-on-disc frictional wear-testing machine was used in air to perform the frictional wear tests of the Ti64 and TNTZ discs mated against Ti64 and TNTZ balls. The wear mechanisms were investigated using a scanning electron microscopy to analyze the worn surfaces and wear debris. The volume losses for the TNTZ discs were larger than those for the Ti64 ones, regardless of the mating ball material. Furthermore, the morphologies of the wear tracks and the debris of the Ti64 and TNTZ discs were different, suggesting that the wear mechanisms for the Ti64 and TNTZ discs were abrasive and delamination wear caused by mild and severe subsurface deformations of the Ti64 and TNTZ, respectively, regardless of the mating ball material.

An Experimental Study on Rough Ball-End Milling of T10A Steel

2011 ◽  
Vol 188 ◽  
pp. 78-83
Author(s):  
Xin Qiang Zhuang ◽  
Chuan Zhen Huang ◽  
Zi Ye Liu ◽  
Bin Zou ◽  
H.L. Liu ◽  
...  
Keyword(s):  
Tool Wear ◽  
Wear Mechanisms ◽  
End Milling ◽  
Orthogonal Experiment ◽  
Cutting Speed ◽  
Main Tool ◽  
Depth Of Cut ◽  
Tool Wear Mechanisms ◽  
Radial Depth ◽  
Coated Cemented Carbide

The milling experiments of the annealed T10A steel were carried out in the various cutting conditions using the coated cemented carbide tool. The cutting parameters were designed by the multi-factor orthogonal experiment method, and the effects of cutting speed, feed, axial depth of cut and radial depth of cut on the cutting force and tool wear were investigated. The tool wear mechanisms were also discussed. Adhesion, abrasion, diffusion and oxidation were the main tool wear mechanisms. According to these investigations, the optimizing cutting parameter was recommended.

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