Tool Wear of Aluminum/Chromium/Tungsten-Based-Coated Cemented Carbide in Cutting Hardened Sintered Steel

2015 ◽  
Vol 772 ◽  
pp. 72-76 ◽  
Author(s):  
Tadahiro Wada ◽  
Hiroyuki Hanyu
Keyword(s):  
Tool Wear ◽  
Cathode Material ◽  
Cutting Speed ◽  
Cemented Carbide ◽  
Coating Film ◽  
Sintered Steel ◽  
High Cutting Speed ◽  
Coated Tools ◽  
Coated Tool ◽  
Coated Cemented Carbide

In order to improve both the scratch strength and the micro-hardness of (Al,Cr)N coating film, the cathode material of an aluminum/chromium/tungsten target was used in adding the tungsten (W) to the cathode material of the aluminum/chromium target. In this study, hardened sintered steel was turned with (Al60,Cr25,W15)N, (Al60,Cr25,W15)(C,N), (Al64,Cr28,W8)(C,N), (Al,Cr)N and (Ti,Al)N coated cemented carbide tools. The tool wear of the coated cemented carbide tool was experimentally investigated. The following results were obtained: (1) In cutting hardened sintered steel at the cutting speed of 0.42 m/s using the (Al60,Cr25,W15)N, the (Al60,Cr25,W15)(C,N), the (Al64,Cr28,W8)(C,N), the (Ti,Al)N and (Al,Cr)N coated tools, the wear progress of the (Al64,Cr28,W8)(C,N) coated tool became slowest among that of the five coated tools. (2) The wear progress of the (Al60,Cr25,W15)(C,N) coated tool was almost equivalent to that of the (Al64,Cr28,W8)(C,N) coated tool. However, at a high cutting speed of 1.67 m/s, the wear progress of the (Al60,Cr25,W16)(C,N) coated tool was faster than that of the (Al64,Cr28,W8)(C,N) coated tool.

Tool Wear of Multi-Layer AlCrWN/AlCrWSiN-Coated Cemented Carbide in Cutting Hardened Sintered Steel

2017 ◽  
Vol 266 ◽  
pp. 69-75 ◽  
Author(s):  
Tadahiro Wada
Keyword(s):  
Flank Wear ◽  
Cutting Speed ◽  
Cemented Carbide ◽  
Coating Film ◽  
Coating System ◽  
Sintered Steel ◽  
Coated Tools ◽  
Coated Tool ◽  
Coated Cemented Carbide ◽  
Layer Coating

In order to clarify the effectiveness of the multi-layer AlCrWN/AlCrWSiN-coated cemented carbide tool, the wear progress was investigated in cutting hardened sintered steel using three types of coated tool. Namely, Tool I had the dual-layer (Al60,Cr25,W15)(C,N)/(Al53,Cr23,W14,Si10)(C,N)-coating film, Tool II had the multi-layer (Al60,Cr25,W15)(C,N)/(Al53,Cr23,W14,Si10)(C,N)-coating film and Tool III had the multi-layer (Al60,Cr25,W15)N/(Al53,Cr23,W14,Si10)N-coating film. The following results were obtained: (1) The main tool failure of the three types of coated tools were the flank wear within the maximum value of the flank wear width of 0.2 mm. (2) The critical scratch load of the three types of coated tools was 130 N or more. (3) The micro-hardness of Tool III 3000 HV0.25N was the highest among the three types of coated tools. (4) The mean value of the friction coefficient of the (Al53,Cr23,W14,Si10)N coating film, 0.21, was approximately half that of the (Al53,Cr23,W14,Si10)(C,N) coating film, 0.41. (5) In the case of the higher cutting speed, the wear progress of the multi-layer coating system was slower than that of the dual-layer coating system. (6) In the case of the cutting hardened sintered steel using the multi-layer coated tool, the wear progress of the Type III coated tool was slower than that of the Type II coated tool.

Tool Wear of Aluminum/Chromium/Tungsten-Based-Coated Cemented Carbide in Cutting Hardened Steel

2015 ◽  
Vol 798 ◽  
pp. 377-383 ◽  
Author(s):  
Tadahiro Wada ◽  
Hiroyuki Hanyu
Keyword(s):  
Tool Wear ◽  
Cathode Material ◽  
Hardened Steel ◽  
Cemented Carbide ◽  
Coating Film ◽  
Carbide Tool ◽  
Micro Hardness ◽  
Cemented Carbide Tools ◽  
Coated Carbide ◽  
Coated Cemented Carbide

An aluminum/chromium based coating film, called (Al,Cr)N coating film, has been developed. This coating film has a slightly more inferior critical scratch load and micro-hardness. Therefore, to improve both the scratch strength and micro-hardness of the (Al,Cr)N coating film, the cathode material of an alumi-num/chromium/tungsten target was used in adding the tungsten (W) to the cathode material of the alumi-num/chromium target. To clarify the effectiveness of the aluminum/chromium/tungsten-based coating film, we measured the thickness, micro-hardness and critical scratch strength of aluminum/chromium/tungsten-based coating film formed on the surface of a substrate of cemented carbide ISO K10 formed by the arc ion plating process. The hardened steel ASTM D2 was turned with the (Al,Cr,W)N, (Al,Cr,W)(C,N), (Al,Cr)N and the (Ti,Al)N coated cemented carbide tools. The tool wear of the coated cemented carbide tools was ex-perimentally investigated. The following results were obtained: (1) The micro-hardness of the (Al,Cr,W)N or (Al,Cr,W)(C,N), (Al,Cr)N coating film was 3110 HV0.25N or 3080 HV0.25N, respectively. (2) The critical scratch load of the (Al,Cr,W)(C,N) coating film was 123 N, which was much higher than that of the (Al,Cr)N or (Ti,Al)N coating film. (3) In cutting the hardened steel using (Al,Cr,W)(C,N) and (Ti,Al)N coated carbide tools, the wear progress of the (Al,Cr,W)(C,N) coated carbide tool was almost equivalent to that of the (Ti,Al)N coated carbide tool. The above results clarify that the aluminum/chromium/tungsten-based coating film, which is a new type of coating film, has both high hardness and good adhesive strength, and can be used as a coating film of WC-Co cemented carbide cutting tools.

Tool Wear of (Al, Cr)N Coated Cemented Carbide in Cutting Sintered Steel

2011 ◽  
Vol 58 (8) ◽  
pp. 459-462 ◽  
Author(s):  
Tadahiro Wada ◽  
Koji Iwamoto ◽  
Hiroyuki Hanyu ◽  
Kinya Kawase
Keyword(s):  
Tool Wear ◽  
Cemented Carbide ◽  
Sintered Steel ◽  
Coated Cemented Carbide

scholarly journals Tool Wear of Aluminum-Chromium Based Coated Cemented Carbide in Cutting Hardened Sintered Steel

2014 ◽  
Vol 6 (3) ◽  
pp. 223-226 ◽  
Author(s):  
Tadahiro Wada ◽  
Mitsunori Ozaki ◽  
Hiroyuki Hanyu ◽  
Kinya Kawase
Keyword(s):  
Tool Wear ◽  
Cemented Carbide ◽  
Sintered Steel ◽  
Coated Cemented Carbide

The Effects of Cutting Conditions on Surface Integrity in Machining Waspaloy

2014 ◽  
Vol 611-612 ◽  
pp. 1243-1249
Author(s):  
Domenico Umbrello
Keyword(s):  
Tool Wear ◽  
Surface Integrity ◽  
Cutting Speed ◽  
Production Costs ◽  
Cutting Conditions ◽  
Dry Cutting ◽  
Important Indicator ◽  
Coated Tools ◽  
Coated Tool ◽  
Environmentally Safe

Machining of advanced aerospace materials have grown in the recent years although the difficult-to-machine characteristics of alloys like titanium or nickel based alloys cause higher cutting forces, rapid tool wear, and more heat generation. Therefore, machining with the use of cooling lubricants is usually carried out. To reduce the production costs and to make the processes environmentally safe, the goal is to move toward dry cutting by eliminating cutting fluids. This objective can be achieved by using coated tool, by increasing cutting speed and by improving the product performance in term of surface integrity and product quality. The paper addresses the effects of cutting speed and feed on the surface integrity during dry machining of Waspaloy using coated tools. In particular, the influence of the cutting conditions on mechanical power consumption, the tool wear and some important indicator of the surface integrity (surface roughness, affected layer, microhardness, grain size and microstructural alteration) were investigated. Results show that cutting conditions have a significant effect on the parameters related to the surface integrity of the product affecting its overall performance.

Performance of Titanium-Tungsten-Silicon-Aluminum Based Coated Cutting Tools

2007 ◽  
Vol 561-565 ◽  
pp. 1241-1244 ◽  
Author(s):  
Tadahiro Wada
Keyword(s):  
Carbon Steel ◽  
Low Carbon Steel ◽  
Carbon Steels ◽  
Cemented Carbide ◽  
Coating Film ◽  
Low Carbon ◽  
Tin Coating ◽  
Coating Films ◽  
Coated Tool ◽  
Coated Cemented Carbide

In order to determine an effective coating film for cutting carbon steels with a coated cemented carbide tool, tool wear was experimentally investigated. Low carbon steel (AISI 5120H steel) was turned with four kinds of physical vapor deposition (PVD) coated cemented carbide tools. The coating films used were TiN coating film and three kinds of titanium-tungsten-silicon-aluminum based coating films, namely (Ti,W,Si,Al)N, (Ti,W,Si,Al)C and (Ti,W,Si,Al)(C,N) coating film. (Ti,W,Si,Al)N, (Ti,W,Si,Al)C or (Ti,W,Si,Al)(C,N) is a new type of coating film. The following results were obtained: (1) The critical load of three kinds of titanium-tungsten-silicon-aluminum based coating films was higher than that of TiN coating film. (2) The hardness of three kinds of titanium-tungsten-silicon-aluminum based coating films was higher than that of TiN coating film. (3) In cutting low carbon steel, the wear progress of three kinds of titanium-tungsten-silicon-aluminum based coating film tools was slower than that of the TiN coated tool. (4) In the three kinds of titanium-tungsten-silicon-aluminum based coating films, the wear progress of the (Ti,W,Si,Al)N coated tool was the slowest.

scholarly journals Wear Mechanism of Multi-layer AlCrWN/AlCrWSiN Coatings on Cemented Carbide Tool Prepared by Arc Ion Plating in Dry Cutting of Sintered Steel

2019 ◽  
Vol 278 ◽  
pp. 02001
Author(s):  
Tadahiro Wada ◽  
Hiroyuki Hanyu
Keyword(s):  
Flank Wear ◽  
Main Tool ◽  
Cemented Carbide ◽  
Coating Film ◽  
Sintered Steel ◽  
Dry Cutting ◽  
Mono Layer ◽  
Cemented Carbide Tool ◽  
Cemented Carbide Tools ◽  
Coated Cemented Carbide

To clarify the effectiveness of multi-layer AlCrWN/AlCrWSiN-coated cemented carbide tools, the wear progress was investigated in cutting sintered steel using three types of coated tool. Tool I had a mono-layer (Al60,Cr25,W15)N-coating film, Tool II had a mono-layer (Al53,Cr23,W14,Si10)N-coating film and Tool III had a multi-layer (Al60,Cr25,W15)N/(Al53,Cr23,W14,Si10)N-coating film. The following results were obtained: (1) The main tool failure of the three types of coated tools was flank wear within a maximum value of flank wear width of 0.2 mm. (2) The wear progress of Type III, which was a multi-layer coating system, was the slowest in cutting sintered steel.

High Speed Milling of Titanium Alloy

2011 ◽  
Vol 325 ◽  
pp. 387-392 ◽  
Author(s):  
Junsuke Fujiwara ◽  
Takaaki Arimoto ◽  
Kazuya Tanaka
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
High Speed ◽  
Elevated Temperatures ◽  
Cutting Speed ◽  
Cemented Carbide ◽  
Carbide Tool ◽  
High Speed Milling ◽  
Cemented Carbide Tool ◽  
Coated Cemented Carbide

Titanium alloys have high strength to weight ratio, corrosion resistance, retention of strength at elevated temperatures and low thermal conductivity. In cutting of the titanium alloy, these characteristics have bad influence on tool wear. Therefore, the titanium alloy is generally machined in the milling at low cutting speed. Recently, the demand of the titanium industrial products is increasing and the high speed milling of the titanium alloy is desired. In this study, the Ti-6Al-4V alloy was machined at high cutting speed, and the tool wear progress and the cutting mechanics were experimentally investigated in order to clarify an effective tool material and cooling method for the cutting of the titanium alloy. The results obtained are as follows: In the cutting with a cemented carbide tool and coated cemented carbide tools of TiAlN, TiCN, DLC at the cutting speed 200 m/min, the wear progress of the coated tools were slower than that of the cemented carbide tool. The titanium alloy was cut in the dry and mist methods in order to avoid the thermal effect of the inserts, the wear progress in mist cutting was longer than that in dry cutting.

The Cutting Behavior of Diamond Coated Tool in Machining Al-20wt%Si Alloy

2010 ◽  
Vol 431-432 ◽  
pp. 365-368
Author(s):  
Wen Zhuang Lu ◽  
Dun Wen Zuo ◽  
B. Yang ◽  
Feng Xu ◽  
M. Wang
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Tool ◽  
Cvd Diamond ◽  
Cemented Carbide ◽  
Depth Of Cut ◽  
Coated Tool ◽  
Coated Cemented Carbide

The performance of CVD diamond coated cemented carbide cutting tool in comparison with K10 uncoated cemented carbide tool in the dry turning of Al-20wt%Si aluminum-silicon hypereutectic alloy was investigated. The obtained results showed a better cutting performance for CVD diamond coated tool in machining Al-20wt%Si, particularly in terms of cutting force, tool wear, surface roughness, when compared with K10. The cutting forces are lower with CVD diamond coated tool and the depth of cut promotes a great increment of the cutting force. The tool wear processes taking place in the tool tips in all cutting conditions. The tool life of CVD diamond coated tool is longer than that of the uncoated K10. The surface roughness Ra increases obviously with the increase of feed rate using a CVD diamond coated cutting tool. A higher feed rate produces surface rougher. The chip morphology in machining of Al-20wt%Si alloy by CVD diamond coated tool is continuous. The tests showed that the CVD diamond coated tool can be applied on the K10 tool at low feed rate to produce high quality surfaces.

Experimental Study on Turning Nickel-Based Superalloy GH4033 with Coated Cemented Carbide Tools

2014 ◽  
Vol 800-801 ◽  
pp. 191-196
Author(s):  
Bin Zhao ◽  
Han Lian Liu ◽  
Chuan Zhen Huang ◽  
Bin Zou ◽  
Hong Tao Zhu
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Failure Modes ◽  
Flank Wear ◽  
Cutting Performance ◽  
Cemented Carbide ◽  
Nickel Based Superalloy ◽  
Coated Tool ◽  
Optimal Cutting Parameters ◽  
Coated Cemented Carbide

The nickel-based superalloy GH4033 is one of the difficult-to-cut materials. In order to investigate the machinability of GH4033, the tool cutting performance, tool failure modes, tool life and the relationships between surface roughness and tool flank wear were studied by using different coated cemented carbide cutting tools under dry cutting. Aiming at the amount of metal removal combining with the tool life and surface quality, the better cutting tool coating type and optimal cutting parameters were obtained through the orthogonal experiments. The results showed that the cutting performance of TiCN coated tool (GC4235) was better than that of TiAlN coated tool (JC450V). With these two kinds of tools, the machined surface roughness decreased to a minimum value and then increased with the increase of flank wear. When cutting GH4033, the main wear mechanism for both of the two types of tools included adhesive wear, diffusive wear, abrasive wear, edge wear and coating peeling.

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