Improvement reliability of cutting ceramic through use of damping system and nanostructured multilayered composite coatings

Alexey Vereschaka,Nikolay Sitnikov,Alexey Krapostin,Gaik Oganyan,Boris Mokritskii

doi:10.1051/meca/2018053

Abstract

This paper considers new avenues of improving the efficiency of machining hardened steels using damping devices and nanostructured multilayered composite coatings deposited on ceramic cutting tools with innovative arc-PVD processes with filtration of vapor-ion flow. A developed technology allows reducing peak stresses arising during cutting-in and providing improved reliability of ceramic tools. It is observed that the formation of modifying coatings on an edge ceramic tool in machining of hardened steels with HRC > 50 under the conditions of damping can reduce the coefficient of tool failure variation down to 0.3, and that improves the ability to predict failure of ceramic tools and allows recommending ceramic tools for the use in automated production.

Highlights

Ceramic tool materials are characterized by a number of important physical and mechanical properties such as high chemical inactivity, enhanced hardness, heat resistance and, respectively, increased wear resistance, and that ensures high performance of the cutting process in the use of a ceramic tool
The purpose of this study is to provide the reliability of mineral-ceramic cutting tool for continuous cutting of workpieces with enhanced hardness based on the use of nanostructured multilayered coatings and dampening effect of cutting system
A damping device is developed, which allows reducing peak stresses arising during cutting-in and providing improved reliability of ceramic tools

Summary

Introduction

Ceramic tool materials are characterized by a number of important physical and mechanical properties such as high chemical inactivity, enhanced hardness, heat resistance and, respectively, increased wear resistance, and that ensures high performance of the cutting process in the use of a ceramic tool. Low cracking resistance of cutting ceramic causes formation of cracks, which because of the absence of plastic binding phase meet no barriers that can slow down or stop their development This phenomenon results in micro- or macrochipping of tool contact areas at the stages of running-in or initial phase of steady wear, resulting in tool failure because of brittle fracture. The main idea of reference [9] is to address the issue of chatter instability by proposing a vibration reduction methodology through the use of embedded piezoelectric patches in the tool holder connected to a passive shunt electrical circuit. This circuit is responsible for energy dissipation providing extra damping to the system. The purpose of this study is to provide the reliability of mineral-ceramic cutting tool for continuous cutting of workpieces with enhanced hardness based on the use of nanostructured multilayered coatings and dampening effect of cutting system

Influence of degree of cutting tool wear on failure rate

Study of influence of machining phases on failure rate

Findings

Conclusions