Tribological Influences of TiAlN Coating on Tool Wear for High-Speed Dry and Wet Machining of Steels

2004 ◽  
Author(s):  
Y. J. Lin ◽  
Samir A. Khrais
Keyword(s):  
High Speed ◽  
High Speed Machining ◽  
Structural Variations ◽  
Edge Chipping ◽  
Coated Tools ◽  
Coated Tool ◽  
Carbide Inserts ◽  
Turning Test ◽  
Cemented Carbide Inserts ◽  
Cutting Speeds

The tribological influences of PVD-applied TiAlN coatings on the wear of cemented carbide inserts and the microstructure wear behaviors of the coated tools under dry and wet machining are investigated. The turning test was conducted with variable high cutting speeds ranging from 210 m/min to 410m/min. The analyses based on the experimental results lead to strong evidences that conventional coolant has a retarded effect on TiAlN coatings under high-speed machining. Microwear mechanisms identified in the tests through SEM micrographs include edge chipping, micro-abrasion, micro-fatigue, micro-thermal, and micro-attrition. These micro-structural variations of coatings provide structure-physical alterations as the measures for wear alert of TiAlN coated tool inserts under high speed machining of steels.

Investigation of Temperature and Stress Distribution on High Speed Machining of Ti6Al4V and 316L Steel Biomaterials Using Explicit Dynamic Analysis

2017 ◽  
Vol 889 ◽  
pp. 84-89
Author(s):  
Pandithevan Ponnusamy ◽  
Mullapudi Joshi
Keyword(s):  
Dynamic Analysis ◽  
Mechanical Behaviour ◽  
High Speed ◽  
Cutting Speed ◽  
Surgical Instruments ◽  
Interface Temperature ◽  
High Speed Machining ◽  
316L Steel ◽  
Explicit Dynamic ◽  
Cutting Speeds

In high speed machining, to dynamically control the mechanical behaviour of the materials, it is essential to control temperature, stress and strain by appropriate speed, feed and depth of cut. In the present work, to predict the mechanical behaviour of Ti6Al4V and 316L steel bio-materials an explicit dynamic analysis with different cutting speeds was carried out. Orthogonal cutting of 316L steel and Ti6Al4V materials with 720 m/min, 900 m/min and 1200 m/min cutting speeds was performed, and the distribution of stress and temperature was investigated using Jonson-Cook material model. Additionally, the work aimed at determining the effect of cutting speed on work piece temperature, when cutting is carried out continuously. From the investigation, it was found that, while machining Ti6Al4V material, for the increase in cutting speed there was increase in tool-chip interface temperature. Specifically, this could found till the cutting speed 900 m/min. But, there was a decrease in tool-chip interface temperature for the increase in speed from 900 m/min to 1200 m/min. Similarly for 316L steel, the tool-chip interface temperature increased when increasing the cutting speed till 900 m/min. But reduction in temperature from 650 °C to 500 °C for steel and 1028 °C to 990 °C for Ti6Al4V were found, when the cutting speed increased from 900 m/min to 1200 m/min. The study can be used to conclude, at what temperature range the adoption of material with controlled shape and geometry is possible for potential applications like, prosthetic design and surgical instruments prior to fabrications.

scholarly journals Cutting Performance Evaluation of the Coated Tools in High-Speed Milling of AISI 4340 Steel

Materials ◽  
2019 ◽  
Vol 12 (19) ◽  
pp. 3266 ◽  
Author(s):  
Yuan Li ◽  
Guangming Zheng ◽  
Xiang Cheng ◽  
Xianhai Yang ◽  
Rufeng Xu ◽  
...  
Keyword(s):  
Performance Evaluation ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Performance ◽  
High Speed Milling ◽  
Coated Tools ◽  
Coated Tool ◽  
Aisi 4340

The cutting performance of cutting tools in high-speed machining (HSM) is an important factor restricting the machined surface integrity of the workpiece. The HSM of AISI 4340 is carried out by using coated tools with TiN/TiCN/TiAlN multi-coating, TiAlN + TiN coating, TiCN + NbC coating, and AlTiN coating, respectively. The cutting performance evaluation of the coated tools is revealed by the chip morphology, cutting force, cutting temperature, and tool wear. The results show that the serration and shear slip of the chips become more clear with the cutting speed. The lower cutting force and cutting temperature are achieved by the TiN/TiCN/TiAlN multi-coated tool. The flank wear was the dominant wear form in the milling process of AISI 4340. The dominant wear mechanisms of the coated tools include the crater wear, coating chipping, adhesion, abrasion, and diffusion. In general, a TiN/TiCN/TiAlN multi-coated tool is the most suitable tool for high-speed milling of AISI 4340, due to the lower cutting force, the lower cutting temperature, and the high resistance of the element diffusion.

High Speed Machining: A Review from a Viewpoint of Chip Formation

2011 ◽  
Vol 188 ◽  
pp. 578-583 ◽  
Author(s):  
Toshiyuki Obikawa ◽  
Masahiro Anzai ◽  
Tsuneo Egawa ◽  
Norihiko Narutaki ◽  
Kazuhiro Shintani ◽  
...  
Keyword(s):  
Tool Wear ◽  
Life Span ◽  
High Speed ◽  
Cutting Speed ◽  
Strong Nonlinearity ◽  
High Speed Machining ◽  
Cast Irons ◽  
Sliding Test ◽  
Cutting Experiments ◽  
Cutting Speeds

This paper describes strong nonlinearity in log V-log L relationship, which is often found in machining of supperalloys, titanium alloys, hardened steels, cast irons, etc. The nonlinearity plays an important and favorable role in extension of life-span cutting distance at higher cutting speeds; that is, in a certain range of cutting speed, life-span cutting distance increases with cutting speed. Results of tool wear in a sliding test and cutting experiments, which showed the evidences of strong nonlinearity, were investigated and the mechanisms causing the nonlinearity were discussed.

Impact of Tool Inserts in High Speed Machining of GFRP Composite Material

2015 ◽  
Vol 787 ◽  
pp. 664-668 ◽  
Author(s):  
K. Anand ◽  
M.V. Siddharth ◽  
K.S. Vijay Sekar ◽  
S. Suresh Kumar
Keyword(s):  
High Speed ◽  
Removal Rate ◽  
Research Work ◽  
Aluminium Nitride ◽  
High Speed Machining ◽  
Feed Force ◽  
Glass Fibre Reinforced Polymer ◽  
Polymer Tube ◽  
Cutting Speeds ◽  
Titanium Aluminium

Composite materials are in-homogenous, anisotropic and cause high tool wear at high cutting speeds in machining. Industrial practices worldwide reveal a need to use high speed machining to achieve the desired material removal rate, surface finish and to reduce cost cutting. In this research work, impact of turning glass fibre reinforced polymer tube with two contrasting turning tool inserts such as titanium aluminium nitride and tungsten carbide have been analysed. The turning was conducted at low to high cutting conditions up to spindle speeds of 2000 rpm and feed rate of 0.446mm/rev. The cutting force, feed force were acquired with a strain gauge based dynamometer, the chip cross section was observed using scanning electron microscopy and the temperature was sensed with a infra red thermo sensor. The advanced titanium aluminium nitride insert shows better machining characteristics across cutting speeds.

Study on the Coated Tool Wear Mechanism of High Speed Milling Ni-Base Superalloy GH625

2012 ◽  
Vol 723 ◽  
pp. 311-316
Author(s):  
Wei Wang ◽  
Ming Hai Wang ◽  
Xiao Peng Li
Keyword(s):  
Wear Mechanisms ◽  
High Speed ◽  
High Speed Milling ◽  
Coated Tools ◽  
Coated Tool ◽  
Tool Wear Mechanism ◽  
Cemented Carbide Tools ◽  
Tools Wear ◽  
Coated Cemented Carbide ◽  
Base Superalloy

The experiments of high speed milling Ni-base superalloy GH625 by using two types of the coated cemented carbide tools at home and abroad, using the scanning electron microscopy (SEM) to observe the tools wear morphology, analyzing the worn surface elements distribution by energy spectrum analysis (EDS) and the main wear mechanisms of the tools. The results show that adhesion, oxidation and diffusion are the main wear mechanisms in initiative wearing stage of the domestic coated tools. And the main wear mechanisms of the imported coated tools are adhesion, oxidation, diffusion and coating spallation.

Tool Life Study of Coated/Uncoated Carbide Inserts during Turning of Ti6Al4V

2014 ◽  
Vol 974 ◽  
pp. 136-140 ◽  
Author(s):  
Suresh Palanisamy ◽  
R.A. Rahman Rashid ◽  
Milan Brandt ◽  
Matthew S. Dargusch
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Diamond Like Carbon ◽  
Dlc Coatings ◽  
Life Study ◽  
Coated Tools ◽  
Coated Tool ◽  
Tool Wear Mechanisms ◽  
Carbide Inserts ◽  
And Diffusion

For more than three decades, the machining industry has been employing coated tools to enhance productivity via improving tool life. Nonetheless, the problems associated with machining titanium alloys have been still prevalent. Advanced alloy materials such as diamond-like carbon (DLC) coatings are developed to combat these issues. In this study, the performance of a DLC coated tool is assessed and its tool wear mechanisms investigated. For the cutting conditions used during these trials, it has been identified that the DLC coated tool exhibited severe tool wear due to delamination and diffusion in comparison with the uncoated carbide tools. In conclusion, it is suggested that the performance of the DLC coated tools can be enhanced by applying alternate strategies to remove heat from the cutting region.

Ultra-High-Speed Machining: A Review and an Analysis of Cutting Forces

1973 ◽  
Vol 187 (1) ◽  
pp. 625-634 ◽  
Author(s):  
G. Arndt
Keyword(s):  
Cutting Forces ◽  
High Speed ◽  
Physical Factors ◽  
High Speed Machining ◽  
Work Related ◽  
Rate Dependent ◽  
High Speeds ◽  
Ultra High Speed ◽  
Very High ◽  
Cutting Speeds

As part of the search for a new cutting mechanism, a few largely empirical investigations into ultra-high-speed machining (velocity greater than 500 ft/s) have been performed in the past. A comprehensive review of this and other work related to machining at very high cutting speeds is presented and the physical factors predominating in UHSM are discussed. As a consequence of this a new theory of cutting forces at ultra-high speeds is presented, based on inertia and temperature effects, adiabatic shear, and strain-rate dependent yield stress. This theory shows that workpiece properties greatly influence force behaviour, the latter determining the feasibility of machining at ultra-high speeds.

Deposition of Diamond Films on Smooth Surfaces of Cemented Carbide Inserts with Cobalt Boride Interlayers

2006 ◽  
Vol 315-316 ◽  
pp. 205-209
Author(s):  
Y. Wang ◽  
Y.P. Ma ◽  
Fang Hong Sun ◽  
Zhi Ming Zhang ◽  
Ming Chen
Keyword(s):  
Surface Roughness ◽  
Diamond Films ◽  
Fold Increase ◽  
Cemented Carbide ◽  
Widespread Application ◽  
Coated Tools ◽  
Key Factor ◽  
Cobalt Boride ◽  
Carbide Inserts ◽  
Cemented Carbide Inserts

Improving adhesion and surface roughness of diamond films on WC–Co substrate is the key factor of the widespread application of diamond coated tools. A new pretreatment method has been performed for smooth Co-cemented carbide inserts in order to lower the surface roughness of diamond films under the premise of good adhesion between diamond films and substrates. The effect of the new pretreatment on the adhesion of the diamond films is investigated. Research results show that the boronization pretreatment can effectively suppress cobalt diffusion to the surface and avoid catalytic effect of Co at high temperature. This new pretreatment can avoid the surface roughening of inserts and ensure the deposition of smooth diamond films. Investigation shows that the optimum boronization compounding is a powder mixture of 70%B4C+15.5%KBF4+1.5% La2O3+13%Na2CO3. Adhesion between substrates and diamond films is evaluated by Rockwell A indentation tests and the cutting performance of the diamond-coated tools is investigated by the cutting tests. Diamond films on smooth cemented carbide inserts with cobalt boride interlayer have high adhesive strength and low surface roughness. Diamond-coated tools with boronization pretreatment have a 5-fold increase in tool life compared with untreated ones.

Chip Length Effect on the Wear of Coated Cemented Carbide Inserts in Milling

2010 ◽  
Vol 438 ◽  
pp. 49-56
Author(s):  
Konstantinos D. Bouzakis ◽  
Stefanos Gerardis ◽  
G. Katirtzoglou ◽  
S. Makrimallakis ◽  
G. Skordaris ◽  
...  
Keyword(s):  
Removal Rate ◽  
Fem Simulation ◽  
Cutting Performance ◽  
Coated Tools ◽  
Coated Tool ◽  
Computational Data ◽  
Material Volume ◽  
Tool Stresses ◽  
Coated Cemented Carbide ◽  
Carbide Inserts

The effect of the developed chip length on the coated tool’s cutting performance was investigated. Milling experiments at various cutting speeds and chip lengths were performed, which resulted to different tool wear developments. To explain these results, a FEM simulation of the cutting process was conducted and the related chip geometries were predicted and compared to the corresponding experimental ones. Based on these results, the Coulomb friction coefficient between chip and tool rake was appropriately adjusted to achieve a sufficient correlation between experimental and computational data. By additional FEM calculations, the mechanical and thermal loads of the cutting edge were estimated and insight was provided concerning the effect of chip length on coated tool stresses and film fatigue fracture. The obtained results revealed that the chip length reduction improves the cutting performance of coated tools and a significant increase of the removed material volume and material removal rate as well can be achieved.

Ultra-High-Speed Machining: A Review and an Analysis of Cutting Forces

1973 ◽  
Vol 187 (1) ◽  
pp. 625-634 ◽  
Author(s):  
G. Arndt
Keyword(s):  
Cutting Forces ◽  
High Speed ◽  
Physical Factors ◽  
High Speed Machining ◽  
Work Related ◽  
Rate Dependent ◽  
High Speeds ◽  
Ultra High Speed ◽  
Very High ◽  
Cutting Speeds

As part of the search for a new cutting mechanism, a few largely empirical investigations into ultra-high-speed machining (velocity greater than 500 ft/s) have been performed in the past. A comprehensive review of this and other work related to machining at very high cutting speeds is presented and the physical factors predominating in UHSM are discussed. As a consequence of this a new theory of cutting forces at ultra-high speeds is presented, based on inertia and temperature effects, adiabatic shear, and strain-rate dependent yield stress. This theory shows that workpiece properties greatly influence force behaviour, the latter determining the feasibility of machining at ultra-high speeds.

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