scholarly journals Investigation of the Wear Performance of TiB2 Coated Cutting Tools during the Machining of Ti6Al4V Alloy

Materials ◽  
2021 ◽  
Vol 14 (11) ◽  
pp. 2799
Author(s):  
Mohammad Shariful Islam Chowdhury ◽  
Bipasha Bose ◽  
German Fox-Rabinovich ◽  
Stephen Clarence Veldhuis
Keyword(s):  
Mechanical Properties ◽  
Tool Life ◽  
Cutting Tools ◽  
Chip Morphology ◽  
High Hardness ◽  
Ti6al4v Alloy ◽  
Wear Volume ◽  
Coating Delamination ◽  
Rough Turning ◽  
Coated Carbide

The machining of Ti6Al4V alloy, especially at low cutting speeds, is associated with strong Built-Up Edge (BUE) formation. The PVD coatings applied on cutting tools to machine such materials must have the necessary combination of properties to address such an underlying wear mechanism. The present work investigates and shows that TiB2 PVD coating can be designed to have certain mechanical properties and tribological characteristics that improve machining in cases where BUE formation is observed. Three TiB2 coatings were studied: one low hardness coating and two high hardness coatings with varied coating thicknesses. Wear performances for the various TiB2 coated carbide tools were evaluated while rough turning Ti6Al4V. Tool wear characteristics were evaluated using tool life studies and the 3D wear volume measurements of the worn surface. Chip morphology analyses were done to assess the in-situ tribological performance of the coatings. The micro-mechanical properties of the coatings were also studied in detail to co-relate with the coatings’ performances. The results obtained show that during the rough turning of Ti6Al4V alloy with intensive BUE formation, the harder TiB2 coatings performed worse, with coating delamination on the rake surface under operation, whereas the softer version of the coating exhibited significantly better tool life without significant coating failure.

scholarly journals Sustainable High-Speed Finishing Turning of Haynes 282 Using Carbide Tools in Dry Conditions

Metals ◽  
2019 ◽  
Vol 9 (9) ◽  
pp. 989 ◽  
Author(s):  
Antonio Díaz-Álvarez ◽  
José Díaz-Álvarez ◽  
José Luis Cantero ◽  
Henar Miguélez
Keyword(s):  
Mechanical Properties ◽  
Tool Life ◽  
High Speed ◽  
Cutting Tools ◽  
Cutting Fluids ◽  
Dry Conditions ◽  
Cutting Zone ◽  
Favorable Conditions ◽  
Coated Carbide ◽  
Cutting Speeds

Nickel-based superalloys exhibit an exceptional combination of corrosion resistance, enhanced mechanical properties at high temperatures, and thermal stability. The mechanical behavior of nickel-based superalloys depends on the grain size and the precipitation state after aging. Haynes 282 was developed in order to improve the creep behavior, formability, and strain-age cracking of the other commonly used nickel-based superalloys. Nevertheless, taking into account the interest of the industry in the machinability of Haynes 282 because of its great mechanical properties, which is not found in other superalloys like Inconel 718 or Waspaloy, more research on this alloy is necessary. Cutting tools suffer extreme thermomechanical loading because of the high pressure and temperature localized in the cutting zone. The consequence is material adhesion during machining and strong abrasion due to the hard carbides included in the material. The main recommendations for finishing turning in Haynes 282 include the use of carbide tools, low cutting speeds, low depth of pass, and the use of cutting fluids. However, because of the growing interest in sustainable processes and cost reduction, dry machining is considered to be one of the best techniques for material removal. During the machining of Haynes 282, at both the finishing and roughing turning, cemented carbide inserts are most commonly used and are recommended all over the industry. This paper deals with the machining of Haynes 282 by means of coated carbide tools cutting fluids (dry condition). Different cutting speeds and feeds were tested to quantify the cutting forces, quality of surface, wear progression, and end of tool life. Tool life values similar to those obtained with a lubricant under similar conditions in other studies have been obtained for the most favorable conditions in dry environments.

scholarly journals Investigation of the Wear Behavior of PVD Coated Carbide Tools during Ti6Al4V Machining with Intensive Built Up Edge Formation

Coatings ◽  
2021 ◽  
Vol 11 (3) ◽  
pp. 266
Author(s):  
M.S.I. Chowdhury ◽  
B. Bose ◽  
S. Rawal ◽  
G.S. Fox-Rabinovich ◽  
S.C. Veldhuis
Keyword(s):  
Tool Wear ◽  
Titanium Alloys ◽  
Wear Behavior ◽  
Cutting Temperature ◽  
Ti6al4v Alloy ◽  
Adhesive Interaction ◽  
Heavy Load ◽  
Micromechanical Properties ◽  
Rough Turning ◽  
Coated Carbide

Tool wear phenomena during the machining of titanium alloys are very complex. Severe adhesive interaction at the tool chip interface, especially at low cutting speeds, leads to intensive Built Up Edge (BUE) formation. Additionally, a high cutting temperature causes rapid wear in the carbide inserts due to the low thermal conductivity of titanium alloys. The current research studies the effect of AlTiN and CrN PVD coatings deposited on cutting tools during the rough turning of a Ti6Al4V alloy with severe BUE formation. Tool wear characteristics were evaluated in detail using a Scanning Electron Microscope (SEM) and volumetric wear measurements. Chip morphology analysis was conducted to assess the in situ tribological performance of the coatings. A high temperature–heavy load tribometer that mimics machining conditions was used to analyze the frictional behavior of the coatings. The micromechanical properties of the coatings were also investigated to gain a better understanding of the coating performance. It was demonstrated that the CrN coating possess unique micromechanical properties and tribological adaptive characteristics that minimize BUE formation and significantly improve tool performance during the machining of the Ti6Al4V alloy.

scholarly journals Performance of Al2O3 nanofluids in minimum quantity lubrication in hard milling of 60Si2Mn steel using cemented carbide tools

2017 ◽  
Vol 9 (7) ◽  
pp. 168781401771061 ◽  
Author(s):  
Duc Tran Minh ◽  
Long Tran The ◽  
Ngoc Tran Bao
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Minimum Quantity Lubrication ◽  
High Hardness ◽  
Cemented Carbide ◽  
Cutting Fluid ◽  
Hard Milling ◽  
Minimum Quantity ◽  
Coated Carbide ◽  
Lubrication Conditions

In this article, an attempt has been made to explore the potential performance of Al2O3 nanoparticle–based cutting fluid in hard milling of hardened 60Si2Mn steel (50-52 HRC) under different minimum quantity lubrication conditions. The comparison of hard milling under minimum quantity lubrication conditions is done between pure cutting fluids and nanofluids (in terms of surface roughness, cutting force, tool wear, and tool life). Hard milling under minimum quantity lubrication conditions with nanofluid Al2O3 of 0.5% volume has shown superior results. The improvement in tool life almost 177%–230% (depending on the type of nanofluid) and the reduction in surface roughness and cutting forces almost 35%–60% have been observed under minimum quantity lubrication with Al2O3 nanofluids due to better tribological behavior as well as cooling and lubricating effects. The most outstanding result is that the uncoated cemented carbide insert can be effectively used in machining high-hardness steels (>50 HRC) while maintaining long tool life and good surface integrity (Ra = 0.08–0.35 µm; Rz = 0.5–2.0 µm, equivalent to finish grinding) rather than using the costlier tools like coated carbide, ceramic, and (P)CBN. Therefore, using hard nanoparticle–reinforced cutting fluid under minimum quantity lubrication conditions in practical manufacturing becomes very promising.

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 Experimental Research on Cutting Superalloy Used New Coated Carbide Tools

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.

The effect of monolayer TiCN-, AlTiN-, TiAlN-and two layers TiCN + TiN- and AlTiN + TiN-coated cutting tools on tool wear, cutting force, surface roughness and chip morphology during high-speed milling of Ti6Al4V titanium alloy

2016 ◽  
Vol 232 (7) ◽  
pp. 1273-1286 ◽  
Author(s):  
Emel Kuram
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Tool Wear ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Tools ◽  
Chip Morphology ◽  
High Speed Milling ◽  
Ti6al4v Titanium Alloy ◽  
Coated Carbide

Tool coatings can improve the machinability performance of difficult-to-cut materials such as titanium alloys. Therefore, in the current work, high-speed milling of Ti6Al4V titanium alloy was carried out to determine the performance of various coated cutting tools. Five types of coated carbide inserts – monolayer TiCN, AlTiN, TiAlN and two layers TiCN + TiN and AlTiN + TiN, which were deposited by physical vapour deposition – were employed in the experiments. Tool wear, cutting force, surface roughness and chip morphology were evaluated and compared for different coated tools. To understand the tool wear modes and mechanisms, detailed scanning electron microscope analysis combined with energy dispersive X-ray of the worn inserts were conducted. Abrasion, adhesion, chipping and mechanical crack on flank face and coating delamination, adhesion and crater wear on rake face were observed during high-speed milling of Ti6Al4V titanium alloy. In terms of tool wear, the lowest value was obtained with TiCN-coated insert. It was also found that at the beginning of the machining pass TiAlN-coated insert and at the end of machining TiCN-coated insert gave the lowest cutting force and surface roughness values. No change in chip morphology was observed with different coated inserts.

Effect of Work Material’s Hardness on Cutting Performance of TiAlN- and CrAlN-Coated Cutting Tools

2015 ◽  
Vol 656-657 ◽  
pp. 231-236
Author(s):  
Risa Koda ◽  
Hiroshi Usuki ◽  
Masahiro Yoshinobu ◽  
Kana Morishita ◽  
Shuho Koseki ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Brinell Hardness ◽  
Cutting Tools ◽  
High Hardness ◽  
Superior Performance ◽  
End Mills ◽  
Arc Evaporation ◽  
Cutting Experiments ◽  
Cutting Speeds ◽  
Selection Of

For better selection of coated cutting tools, TiAlN (Ti50Al50N) and CrAlN (Cr50Al50N) coatings were deposited onto ball-nose and square end mills using arc evaporation, and their cutting performances were evaluated using steel workpieces of various hardnesses. In particular, cutting tests were performed on three types of workpieces, made from S50C, SKD61, and SKD11 steels, having Brinell hardness numbers of HB220, HRC40, and HRC60, respectively. The results of the cutting experiments were elucidated and discussed in terms of the mechanical properties and anti-oxidation resistances of the different coatings. The results revealed that TiAlN-coated square end mills at high cutting speeds (V = 200 m/min ) had superior performance when used on steels with high hardness (SKD11), whereas CrAlN-coated ball-nose end mills were superior when used on low hardness steel (S50C). Therefore, CrAlN-coated ball-nose end mills are concluded to be suitable for the machining of low hardness steels, whereas TiAlN-coated square end mills are preferable for the machining of high hardness steels (SKD11).

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.

Investigation of Tool Wear, Tool Life and Surface Roughness when Machining AISI D2 Hardened Steel Using PVD TiAlN Coated Carbide Tools

2013 ◽  
Vol 465-466 ◽  
pp. 1098-1102 ◽  
Author(s):  
Noor Hakim Rafai ◽  
Mohd Amri Lajis ◽  
N.A.J. Hosni
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Tool Life ◽  
Material Removal ◽  
Cutting Tools ◽  
Hardened Steel ◽  
Tool Failure ◽  
Aisi D2 ◽  
Wear Tool ◽  
Coated Carbide

This paper discussed the behavior of cutting tool in terms of tool wear, tool life and surface roughness when machining an AISI D2 hardened steel. An experimental test was conducted at different cutting speeds (Vc) and radial depth of cut (ae) using PVD TiAlN coated carbide tool under dry condition. Tool failure modes and tool wear mechanism for all cutting tools were examined at various cutting parameters. Flank wear was found to be the predominant tool failure for cutting tools. The highest volume material removal (VMR) attained was 3750 mm3 meanwhile the highest tool life (TL) was 9.69 min. The surface roughness (Ra) values from 0.09 to 0.24 μm can be attained in the workpiece with a high material removal. The relationship of tool wear performance and surface integrity was established to lead an optimum parameter in order to have high material removal, maximum tool life as well as acceptable surface finish.

Tool Wear and Surface Integrity in High Speed Milling of Forging and Cast TA15 Alloys with Coated Carbide Tools

2009 ◽  
Vol 626-627 ◽  
pp. 189-194
Author(s):  
P. Liu ◽  
Jiu Hua Xu ◽  
Yu Can Fu
Keyword(s):  
Titanium Alloy ◽  
Tool Life ◽  
Surface Integrity ◽  
High Speed ◽  
Cutting Tools ◽  
High Speed Milling ◽  
Alpha Titanium ◽  
Series Of Experiments ◽  
Coated Carbide ◽  
Coated Carbide Tools

TA15 (Ti-6.5Al-2Zr-1Mo-1V) is a close alpha titanium alloy strengthened by solid solution with Al and other component. A series of experiments were carried out on normal and high speed milling of TA15. The recommended tools for many years had been the uncoated tungsten carbide grade K. In this work, the tool life of coated carbide tools used in high speed milling of forging and cast titanium alloy was studied. Additionally, the wear mechanism of cutting tools was also discussed. Finally, surface integrity, including surface roughness, metallograph and work hardening, were examined and analyzed. The result shows that the surface quality of forging and cast machined by carbide cutter is similar, but the tool life of carbide in high speed milling of forging TA15 is longer than that in high speed milling of cast TA15.

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