Comparative assessment between AlTiN and AlTiSiN coated carbide tools towards machinability improvement of AISI D6 steel in dry hard turning

2021 ◽  
pp. 095440622110373
Author(s):  
Anshuman Das ◽  
Miyaz Kamal ◽  
Sudhansu Ranjan Das ◽  
Saroj Kumar Patel ◽  
Asutosh Panda ◽  
...  
Keyword(s):  
Cutting Force ◽  
Tool Life ◽  
Hard Turning ◽  
Flank Wear ◽  
Chip Morphology ◽  
Comparative Assessment ◽  
Carbide Tool ◽  
Crater Wear ◽  
Coated Carbide ◽  
Coated Carbide Tools

AISI D6 (hardness 65 HRC) is one of the hard-to-cut steel alloys and commonly used in mould and die making industries. In general, CBN and PCBN tools are used for machining hardened steel but its higher cost makes the use for limited applications. However, the usefulness of carbide tool with selective coatings is the best substitute having comparable tool life, and in terms of cost is approximately one-tenth of CBN tool. The present study highlights a detailed analysis on machinability investigation of hardened AISI D6 alloy die steel using newly developed SPPP-AlTiSiN coated carbide tools in finish dry turning operation. In addition, a comparative assessment has been performed based on the effectiveness of cutting tool performance of nanocomposite coating of AlTiN deposited by hyperlox PVD technique and a coating of AlTiSiN deposited by scalable pulsed power plasma (SPPP) technique. The required number of machining trials under varied cutting conditions (speed, depth of cut, feed) were based on L16 orthogonal array design which investigated the crater wear, flank wear, surface roughness, chip morphology, and cutting force in hard turning. Out of the two cutting tools, newly-developed nanocomposite (SPPP-AlTiSiN) coated carbide tool promises an improved surface finish, minimum cutting force, longer tool life due to lower value of crater & flank wears, and considerable improvement in tool life (i.e., by 47.83%). At higher cutting speeds, the crater wear length and flank wear increases whereas the surface roughness, crater wear width and cutting force decreases. Chip morphology confirmed the formation of serrated type saw tooth chips.

Comparative Assessment of Coated CBN and Multilayer Coated Carbide Tools on Tool Wear in Hard Turning AISID2 Steel

2018 ◽  
Author(s):  
M.Junaid Mir ◽  
M.F. Wani ◽  
Summera Banday ◽  
Shuhaib Mushtaq ◽  
Jebran Khan ◽  
...  
Keyword(s):  
Tool Wear ◽  
Hard Turning ◽  
Comparative Assessment ◽  
Coated Carbide ◽  
Coated Carbide Tools

Edge Preparation on Cutting Force, Cutting Temperature and Tool Wear for Hard Turning

2014 ◽  
Vol 800-801 ◽  
pp. 424-429
Author(s):  
Pei Rong Zhang ◽  
Zhan Qiang Liu
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Hard Turning ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Cutting Edge ◽  
Crater Wear ◽  
Cutting Edge Preparation ◽  
Flank Face ◽  
Edge Preparation

The paper investigates the effects of cutting edge preparation on cutting force, cutting temperature and tool wear for hard turning. An optimized characterization approach is proposed and five kinds of cemented tools with different edge preparation are adopted in the simulations by DEFROM-2DTM. The results show that both the forces and cutting temperature on the rake face climb up and then declines with the increasing of factor K (Sγ/Sα). While the temperature on flank face decrease with the increasing of the factor K. When the cutting conditions are identical, flank wear reduces while crater wear exacerbates before easing with the increasing of the factor K. The simulation results will provide valuable suggestions for optimization of cutting edge preparation for hard turning in order to obtain excellent machining quality and longer tool life.

Performance evaluation of a tungsten carbide–based self-lubricant cutting tool

2016 ◽  
Vol 232 (10) ◽  
pp. 1825-1836 ◽  
Author(s):  
Ayyankalai Muthuraja ◽  
Selvaraj Senthilvelan
Keyword(s):  
Tungsten Carbide ◽  
Cutting Force ◽  
Tool Life ◽  
Solid Lubricant ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Tools ◽  
Chip Morphology ◽  
Machined Surface ◽  
Flank Surface

Tungsten carbide cutting tools with and without solid lubricant (WC-10Co-5CaF2 and WC-10Co) were developed in-house via powder metallurgy. The developed cutting tools and a commercial WC-10Co cutting tool were used to machine cylindrical AISI 1020 steel material under dry conditions. The cutting force and average cutting tool temperature were continuously measured. The cutting tool flank surface and chip morphology after specific tool life (5 min of cutting) were examined to understand tool wear. The flank wear of the considered cutting tools was also measured to quantify the cutting tool life. The surface roughness of the workpiece was measured to determine the machining quality. The developed cutting tool with solid lubricant (WC-10Co-5CaF2) generated 20%–40% less cutting force compared to that of the developed cutting tool without solid lubricant (WC-10Co). In addition, the finish of the workpiece surface improved by 16%–20% when it was machined by the solid lubricant cutting tool. The cutting tool with solid lubricant (WC-10Co-5CaF2) exhibited a 15%–18% reduction in flank wear. Curlier and smaller saw tooth chips were generated from the WC-10Co-5CaF2 cutting tool, confirming that less heat was generated during the cutting process, and the finish of the machined surface was also improved.

Study on the Tool Wear of Coated Carbide Tool in High Speed Milling Titanium Alloy

2014 ◽  
Vol 800-801 ◽  
pp. 526-530 ◽  
Author(s):  
Shu Cai Yang ◽  
Yu Hua Zhang ◽  
Quan Wan ◽  
Jian Jun Chen ◽  
Chuang Feng
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Tool Life ◽  
High Speed ◽  
Carbide Tool ◽  
High Speed Milling ◽  
Coated Carbide Tool ◽  
Fluid Environment ◽  
Coated Carbide ◽  
Coated Carbide Tools

The milling experiments were carried out using TiAlN and PCD coated carbide tools in high speed milling Ti6Al4V to compare and analyze tool wear and tool life of the two kinds of coating carbide tools. In addition, the effect of cooling and lubricating on tool wear is also studied. The results showed that fluid environment is not suitable for milling Ti6Al4V. PCD coating carbide tool can effectively increase the life of tool in high speed milling of Ti6Al4V.

Wear Characteristics of Coated Carbide Tools in the Face Milling of Ductile Cast Iron

2017 ◽  
Vol 749 ◽  
pp. 178-184 ◽  
Author(s):  
Israel Martinez ◽  
Ryutaro Tanaka ◽  
Yasuo Yamane ◽  
Katsuhiko Sekiya ◽  
Keiji Yamada ◽  
...  
Keyword(s):  
Cast Iron ◽  
Flank Wear ◽  
Ductile Cast Iron ◽  
Face Milling ◽  
Carbide Tool ◽  
Coated Tools ◽  
Coated Carbide Tool ◽  
The Face ◽  
Coated Carbide ◽  
Coated Carbide Tools

This study reports an experimental investigation about the wear behavior of TiN and TiCN coated carbide tools during the face milling of pearlitic and ferritic ductile cast iron. Pearlitic ductile cast iron caused the highest cutting forces and flank wear in both TiN and TiCN coated tools. Due to its protective effect, the TiCN coated carbide tool outperformed the TiN coated carbide tool regarding flank wear. The main issue when face milling ferritic ductile cast iron with TiN coated tools was notching wear. The principal reason for notch wear was pointed as adhesive wear caused for the high tendency of ferrite to adhere on the tool. The results demonstrated that the TiCN coating did not showed notching wear when face milling ferritic ductile cast iron, therefore a good choice of coating material can prevent notching wear.

scholarly journals Comparative assessment of hard turning under dry and minimum quantity lubrication

2021 ◽  
Vol 1206 (1) ◽  
pp. 012007
Author(s):  
Avez Shaikh ◽  
Ajinkya Shinde ◽  
Satish Chinchanikar ◽  
Guruprasad Zagade ◽  
Sonia Pardeshi
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Tool Life ◽  
Hard Turning ◽  
Cutting Speed ◽  
Comparative Assessment ◽  
Depth Of Cut ◽  
Machining Performance ◽  
Dry Cutting ◽  
Optimal Surface

Abstract Hard turning with CBN and ceramic inserts is commonly regarded as a cost-effective alternative to grinding. However, there have been few studies comparing hard turning with low-cost carbide tools to high-cost CBN and ceramic cutting tools. However, when it comes to the usage of cutting coolant during severe turning, there are mixed outcomes. In this study, a PVD-coated TiSiN-TiAlN carbide tool was used to hard turn AISI 52100 steel in a dry and MQL environment. Through multi-objective optimization, a comparative assessment in terms of surface roughness, cutting force, and tool life under various cutting settings is provided. In terms of three components of cutting force, surface roughness, and tool life, mathematical models were constructed to forecast and improve machining performance. Under both dry and MQL conditions, the study discovered an optimal cutting speed of 108 m/min, a feed value of 0.09 mm/rev, and a depth of cut of 0.16 mm. Under MQL, hard turning produced optimal surface roughness and tool life of 0.88 m and 64 minutes, respectively. In comparison to hard turning under dry cutting, the optimal surface roughness was 1.07 m and the tool life was 49 minutes. Under MQL, tool life increased by over 31%, according to the findings of the experiments. Under dry and MQL conditions, however, no significant differences in cutting forces and surface roughness were identified.

Effect of High-Pressure Coolant Supply on Chip-Breaking and Tool Wear in Machining of Stainless Steel

2015 ◽  
Vol 656-657 ◽  
pp. 226-230 ◽  
Author(s):  
Takahiro Katoh ◽  
Shigetoshi Ohmori ◽  
Takahiro Maeda ◽  
Takanori Kakumitsu ◽  
Koichi Okuda ◽  
...  
Keyword(s):  
High Pressure ◽  
Stainless Steel ◽  
Tool Wear ◽  
Cutting Force ◽  
Tool Life ◽  
Flank Wear ◽  
Crater Wear ◽  
Cutting Inserts ◽  
On Chip ◽  
High Pressure Coolant

The high-pressure coolant supply cutting has attracted attention from a viewpoint of chip evacuation and tool life. In this study, the influence of high-pressure coolant supply on chip shape, cutting force and tool wear were investigated. The tests were carried out during external turning of stainless steel with cemented carbide cutting inserts. The results suggest that the length and radius of the chips got shorter with high-pressure coolant supply, especially supply pressure more than 5MPa. The cutting force was increase slightly with high-pressure coolant supply. However the thrust force was decrease. The uniform flank wear and crater wear were reduced and tool life was improved by high-pressure coolant supply.

Tool Life Improvement of Coated Carbide Tools Treated by Novel Nitriding Technique

2009 ◽  
Vol 407-408 ◽  
pp. 24-27
Author(s):  
Katsuhiko Sakai ◽  
Yasuo Suzuki ◽  
Hisaya Inoue ◽  
Katsuyoshi Utino ◽  
Yasuyuki Horikoshi
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Cutting Tools ◽  
Carbide Tool ◽  
Dry Cutting ◽  
Coating Technology ◽  
Coated Carbide Tool ◽  
Life Improvement ◽  
Coated Carbide ◽  
Coated Carbide Tools

This paper describes the effects of novel nitriding technique used in various carbide cutting tools. In manufacturing, eco-friendly machining is demanded of late. So far, many kinds of methods were made practical, for example MQL process. Through the development of coating technology, dry cutting process has been used and even now more improvement of tool life is required. Both coated and the non-coated carbide tool were applied with novel nitriding to elongate their tool life. The results show novel nitriding decreased the coated carbide tool wear and improved its tool life 1.4 times longer than non-treated carbide. Similarly, the non-coated carbide tool wear decreased and built-up edge on tool surface reduced. These improvements may be derived from the hardening effect on the binder material within the carbide tools.

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