scholarly journals Investigation into Performance of Multilayer Composite Nano-Structured Cr-CrN-(Cr0.35Ti0.40Al0.25)N Coating for Metal Cutting Tools

Coatings ◽  
2018 ◽  
Vol 8 (12) ◽  
pp. 447 ◽  
Author(s):  
Sergey Grigoriev ◽  
Alexey Vereschaka ◽  
Alexander Metel ◽  
Nikolay Sitnikov ◽  
Filipp Milovich ◽  
...  
Keyword(s):  
Tool Life ◽  
Metal Cutting ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Constructional Steel ◽  
Wear Process ◽  
Layered Architecture ◽  
Process Pattern ◽  
Resistant Layer ◽  
Cutting Speeds

This paper deals with the Cr-CrN-(Cr0.35Ti0.40Al0.25)N coating. It has a three-layered architecture with a nano-structured wear-resistant layer. The studies involved the investigation into the microstructure (with the use of SEM and TEM), elemental and phase composition (XRD and SAED patterns), wear process pattern in scratch testing, crystal structure, as well as the microhardness of the coating. Cutting tests of tools with the above coating were carried out in dry turning of steel 1045 at cutting speeds of vc = 200, 250, and 300 m·min−1. The comparison included uncoated tools and tools with the commercial TiN and (Ti,Al)N coatings with the same thickness. The tool with the Cr-CrN-(Cr0.35Ti0.40Al0.25)N coating showed the longest tool life at all the cutting speeds under consideration. Meanwhile, a tool with the coating under study can be recommended for use in turning constructional steel at the cutting speed of vc = 250 m·min−1. At this cutting speed, a tool shows the combination of a rather long tool life and balanced wear process, without any threat of catastrophic wear.

scholarly journals Influence of the Thickness of Multilayer Composite Nano-Structured Coating Ti–TiN–(Ti,Al,Si)N on the Tool Life of Metal-Cutting Tools and the Nature of Wear

Coatings ◽  
2019 ◽  
Vol 9 (11) ◽  
pp. 730 ◽  
Author(s):  
Alexey Vereschaka ◽  
Sergey Grigoriev ◽  
Nikolay Sitnikov ◽  
Anatoliy Aksenenko ◽  
Filipp Milovich ◽  
...  
Keyword(s):  
Tool Life ◽  
Metal Cutting ◽  
Cutting Tools ◽  
Multilayer Composite ◽  
Scratch Testing ◽  
Wear Resistant ◽  
And Performance ◽  
Resistant Layer ◽  
Carbide Inserts ◽  
Cutting Speeds

This article discusses the influence of the thickness of a nano-structured wear-resistant layer of the Ti–TiN–(Ti,Al,Si)N multilayer composite coating on its mechanical and performance properties. The study was focused on the coatings with the following thicknesses of its wear-resistant layers: 2, 3.5, 5, 7, 11, and 15 μm. The relation between the thickness of a wear-resistant layer and the time of its deposition was investigated, and the effect of the above thickness on hardness and wear resistance in scratch testing was considered. Cutting tests were conducted in turning steel C45 with carbide inserts with the coatings under study at various cutting speeds (vc = 250, 300 and 350 m/min). The study found the value of thickness of wear-resistant layer providing the longest tool life at various cutting speeds. The differences in the nature of wear for the coatings with various thicknesses of wear-resistant layers were considered.

Development of Cutting Tools With Micro-Textured Surface for High Speed Machining of Ti-6Al-4V

2021 ◽  
Author(s):  
Mitsuru Hasegawa ◽  
Tatsuya Sugihara
Keyword(s):  
Tool Life ◽  
High Speed ◽  
Metal Cutting ◽  
Failure Process ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Textured Surface ◽  
Textured Surfaces

Abstract In cutting of Ti-6Al-4V alloy, the cutting speed is limited since a high cutting temperature leads to severe tool wear and short tool life, resulting in poor production efficiency. On the other hand, some recent literature has reported that various beneficial effects can be provided by forming micro-textures on the tool surface in the metal cutting process. In this study, in order to achieve high-performance machining of Ti-6Al-4V, we first investigated the mechanism of the tool failure process for a cemented carbide cutting tool in high-speed turning of Ti-6Al-4V. Based on the results, cutting tools with micro textured surfaces were developed under the consideration of a cutting fluid action. A series of experiments showed that the textured rake face successfully decreases the cutting temperature, resulting in a significant suppression of both crater wear and flank wear. In addition, the temperature zone where the texture tool is effective in terms of the tool life in the Ti-6Al-4V cutting was discussed.

scholarly journals Analysis of the General Tool Life Function of Cutting Tools by Application of the Catastrophe-Theory

2021 ◽  
Author(s):  
Zoltán Pálmai ◽  
János Kundrák ◽  
Csaba Felhő
Keyword(s):  
Tool Life ◽  
Catastrophe Theory ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Taylor Formula ◽  
Technology Planning ◽  
Concave Part ◽  
Cutting Speeds ◽  
General Tool ◽  
Life Function

Abstract Production technology planning requires information on tool life T and its relation to cutting speed v. As the Taylor formula often cannot be linearized on an lg-lg scale, a general tool life function has been developed for describing a v-T function with a convex-concave part. Using catastrophe theory, an analogy is established between the general tool life function and the cusp catastrophe, allowing topological mapping of the general v-T function. Results were verified by machinability tests in the turning of C35 and C60 conventional and specially deoxidized C-steels during steelmaking. It was found that in the convex-concave section of this function, 2–3 cutting speeds can be selected for a given tool life, which is advantageous for harmonizing tool changes in multi-operation technology.

Micro Quantity Internal Cooling (MQUIC™) of Cutting Tools for Increased Productivity While Machining Ti-6Al-4V

2010 ◽  
Author(s):  
Samved Bhatnagar ◽  
William J. Endres
Keyword(s):  
Tool Life ◽  
Unit Cost ◽  
Cutting Tools ◽  
Cutting Speed ◽  
High Strength ◽  
Internal Cooling ◽  
Wear Rates ◽  
Industry Standard ◽  
Tool Performance ◽  
Cutting Speeds

Machining of space age materials like Ti-6Al-4V is associated with thermally activated wear mechanisms which lead to rapid tool failure and increased machine downtime. The high strength and low thermal conductivity of Ti-6Al-4V can reduce tool-life significantly at high cutting speeds adding drastically to the per-unit cost. A new concept, Micro Quantity Internal Cooling (MQUIC™) has been developed to extend the tool-life and/or enable higher cutting speeds while machining Ti-6Al-4V. The concept involves introducing flow (coolant) in a micro-duct placed inside the tool and close to the cutting edge, thus bringing the cooling source close to the heat source (chip-contact area). In this research, experiments have been conducted to compare the performance (wear rates) of cutting tools using the MQUIC™ concept with those run under dry or flood conditions. Further, two levels of feed and cutting speed are selected for the experiments so as to be able to investigate the combined effect of parameters on tool performance. Physical testing employing coolant consumption of less than 5% of typical flood coolant rates proves the viability of the concept by demonstrating wear rates of 1/3 to 1/2 those of flood cooling. The testing also proves the application of the MQUIC™ concept to enable higher cutting speeds than the current industry standard for machining Ti-6Al-4V. This paper presents the experimental setup, methodology and results obtained while testing the feasibility of the concept.

scholarly journals Alternative Binder Carbide Tools for Machining Superalloys

2008 ◽  
Author(s):  
Daniel Waldorf ◽  
Scott Liu ◽  
Michael Stender ◽  
Daniel Norgan
Keyword(s):  
Wear Resistance ◽  
Tool Life ◽  
Cutting Tools ◽  
Cutting Speed ◽  
New Class ◽  
Nickel Based Superalloy ◽  
Composite Tool ◽  
Binder Composition ◽  
Positive Effect ◽  
Cutting Speeds

This study examines the performance of a new class of wear-resistant but economical cutting tools produced by varying the binder composition of standard cemented carbide composites. By replacing some or all of the cobalt binder with rhenium and nickel-based superalloy, a stronger composite tool results, potentially capable of machining heat-resistant superalloys at significantly higher cutting speeds. Sample tools with alternative binder were produced and compared to standard tools bound with cobalt only. Turning experiments on Inconel 718 were run to evaluate wear resistance and tool life for several grades. The experimentation also examined the effects of varying the relative proportions of each binder constituent as well as the overall binder percentage in the composite. Results show a clear advantage of the alternative binder tools as evidenced by a 150% increase in tool life or the equivalent of an 18% increase in cutting speed. Although increasing amounts of rhenium in the binder show a positive effect on performance, the effects of superalloy and overall binder % are inconclusive.

scholarly journals Influence of Thickness of Multilayered Nano-Structured Coatings Ti-TiN-(TiCrAl)N and Zr-ZrN-(ZrCrNbAl)N on Tool Life of Metal Cutting Tools at Various Cutting Speeds

Coatings ◽  
2018 ◽  
Vol 8 (1) ◽  
pp. 44 ◽  
Author(s):  
Alexey Vereschaka ◽  
Elena Kataeva ◽  
Nikolay Sitnikov ◽  
Anatoliy Aksenenko ◽  
Gaik Oganyan ◽  
...  
Keyword(s):  
Tool Life ◽  
Metal Cutting ◽  
Cutting Tools ◽  
Cutting Speeds

Investigation on the Tool Wear Model and Equivalent Tool Life in End Milling Titanium Alloy Ti6Al4V

2018 ◽  
Author(s):  
Kai Guo ◽  
Bin Yang ◽  
Jie Sun ◽  
Vinothkumar Sivalingam
Keyword(s):  
Tool Wear ◽  
Titanium Alloys ◽  
Tool Life ◽  
End Milling ◽  
Cutting Speed ◽  
Carbide Tool ◽  
Wear Model ◽  
Wear Process ◽  
Coated Carbide Tool ◽  
Coated Carbide

Titanium alloys are widely utilized in aerospace thanks to their excellent combination of high-specific strength, fracture, corrosion resistance characteristics, etc. However, titanium alloys are difficult-to-machine materials. Tool wear is thus of great importance to understand and quantitatively predict tool life. In this study, the wear of coated carbide tool in milling Ti-6Al-4V alloy was assessed by characterization of the worn tool cutting edge. Furthermore, a tool wear model for end milling cutter is established with considering the joint effect of cutting speed and feed rate for characterizing tool wear process and predicting tool wear. Based on the proposed tool wear model equivalent tool life is put forward to evaluate cutting tool life under different cutting conditions. The modelling process of tool wear is given and discussed according to the specific conditions. Experimental work and validation are performed for coated carbide tool milling Ti-6Al-4V alloy.

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.

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.

A Stochastic Tool-Life Model

1981 ◽  
Vol 103 (1) ◽  
pp. 126-130 ◽  
Author(s):  
S. Rossetto ◽  
A. Zompi
Keyword(s):  
Stochastic Model ◽  
Failure Rate ◽  
Tool Life ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Edge ◽  
Model Based ◽  
Life Model ◽  
Theoretical Standpoint

A tool-life model based on the assumption that wear and fracture are the causes of tool death is re-examined from the theoretical standpoint, and extended to include the effect of cutting speed on the fracture-induced failure rate. A stochastic model for multi edge cutting tools is also proposed. This enables the overall statistics to be derived from the data for each individual cutting edge.

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