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Correlation between Coating Properties and Industrial Applications
Published in Sam Zhang, Jyh-Ming Ting, Wan-Yu Wu, Protective Thin Coatings Technology, 2021
Yin-Yu Chang, Heng-Li Huang, Jui-Ting Hsu, Ming-Tzu Tsai
In recent years, a broad growing market of coated cutting tools has been developed, and the hard coatings of cutting tools were driven by the demand on the increased usage of difficult-to-cut materials. In the case of cutting difficult-to-cut materials of Inconel super alloy, a nickel-based alloy which is difficult to shape because of its high tribological and thermal properties. Erosion of the cutting edge occurs due to diffusion wear after abrasive wear. Decrease of cutting force and limitation built-up edge (BUE) phenomenon are necessary. AlTiN coating possessing high temperature oxidation resistance shows good tribological behavior and it prevents sticking phenomena on rake face of the cutting tool. Microabrasive blasting can be adopted as a surface modification as well as the AlTiN coating treatment technique [58]. Sanchette et al. [59] showed that a nanolayered TiN/AlTiN coating is a proper coating design for cutting Inconel alloys. This coating induces the lowest cutting force on the tool and limits adhesive BUE phenomenon. This coating is also very effective for avoiding strong abrasive wear due to high hardness and toughness of the coating material.
Mechanics of Cutting
Published in David A. Stephenson, John S. Agapiou, Metal Cutting Theory and Practice, 2018
David A. Stephenson, John S. Agapiou
The built-up edge is an accumulation of heavily strained work material, which collects on the cutting edge under proper conditions. It is an undesirable feature for several reasons. It reduces machining accuracy by changing the effective feed rate. It also reduces the quality of the machined surface because it periodically breaks off and reforms, introducing irregularities into the surface. The periodic breakage can also lead to chipping of the cutting edge. Finally, built-up edge may also promote the thermal cracking of the tool.
Machinability analysis and application of response surface approach on CNC turning of LM6/SiCp composites
Published in Materials and Manufacturing Processes, 2019
Balasubramanian K, Nataraj M, Palanisamy Duraisamy
The crater and flank wear are described as the vital measures of the life of tool, and it depends on machining conditions, hardness of the work specimen, geometry of tool, and also type of tool.[24]The reinforced silicon carbide particles are harder than tungsten carbide insert) and behave like a cutting edge during machining of MMC. The SEM and EDAX analysis for LM6/SiC MMC are presented in Fig. 9. The work piece has been stick over the rake face of the cutting inserts in machining of MMC. During machining, the ductile property of MMC generated high shearing stress and temperature evolved at the secondary malformation region especially at the chip-tool interface region. The work material adhered or built-up-edge (BUE) due to high stress, cutting pressure, and temperature among the cutting tool insert and work-piece.[25] This adhesion property of work material is accelerated at lower machining velocity, because at lower machining velocity higher cutting force and higher cutting temperature is produced.[26]The formation of built-up-edge deteriorated the surface finish quality and increased the cutting force.[27]
Effect of machining parameters on turning of VAT32® superalloy with ceramic tool
Published in Materials and Manufacturing Processes, 2019
Eduardo Pires Bonhin, Sarah David-Müzel, José Vitor Candido De Souza, Manoel Cléber De Sampaio Alves, Marcos Valério Ribeiro
Another type of tool wear that occurred at the edges of the cutting tools was the Built-up edge. The alteration initially evidenced this in the color of the tool and later confirmed by the performance of EDS (Energy Dispersive Spectroscopy). In which were found traces of elements belonging to VAT-32® (Fig. 7).
Performance analysis of centrifugal-cast single-point cutting-tools developed from scrapped tools
Published in Materials and Manufacturing Processes, 2022
Shubhashree Mohapatra, Hrushikesh Sarangi, Upendra Kumar Mohanty
Tool wear at different cutting velocities is investigated while turning MS workpiece using the T1 and T2 tool. The time period of 70 minutes is considered to study the performance of both cutting tools at different cutting velocities from 31.41 m/min to 63.93 m/min. Both tools work satisfactorily at cutting velocities 31.41 m/min, 40.8 m/min, and 52.77 m/min. However, at cutting velocity 63.93 m/min, the T1 tool and T2 tool failed to cut the material after 14.14 minutes and 6 minutes respectively requiring a very high cutting force for machining. Figure 5 shows the influence of cutting velocity on flank wear of the T1 tool and T2 tool. According to the observation, the T1 tool experienced a slightly higher wear rate compared to the T2 tool at the cutting velocity range of 31.41 m/min to 52.77 m/min. However, the rate of tool wear decreases for the T1 tool as compared to the T2 tool at a cutting velocity of 63.93 m/min. Apart from that, catastrophic failure and a sudden breaking of the cutting edge of the T2 tool are observed instead of gradual tool wear at 63.93 m/min. A similar trend of failure mode is also observed by several researchers.[13] The main cause of catastrophic failure of the T2 cutting tool could be due to thermo-chemical wear that occurred with an increase in interface temperature at high cutting velocities.[14] The centrifugal force exerted during the casting of the centrifugal cast tool resulted in density-wise segregation of the carbides formed by the above listed element which increases the toughness of the tool. The increased toughness of the developed centrifugal cast tool prevents the catastrophic failure of the tool unlike the conventional cast HSS M2 tool at higher cutting velocity. In addition to that, a built-up edge (BUE) formation at the cutting edges is noticed for each tool due to the adhesion tendency of ductile workpiece material on the cutting edges. Bayraktar and Demir[15] reported the increase in cutting zone temperature might lead to an increase in ductility of material and thus, the BUE formation while turning of Al-12Si-0.6 Mg alloy. At low cutting velocity, the performance of the T1 tool is comparable with the T2 tool. The flank wear width (VB) of the T2 tool increases from 0.08 mm to 0.38 mm when cutting velocity rises from 31.41 m/min to 63.93 m/min respectively. Similarly, for the T1 tool, the VB value progresses from 0.12 to 0.28 mm with the increase in cutting velocity from 31.41 m/min to 63.93 m/min respectively.