Abstract
The study deals with an increase in the tool life parameter for metal-cutting tools and efficiency of end milling for titanium alloys, due to the use of tools with multilayered composite nano-structured Zr–ZrN–(Zr,Al)N and Zr–ZrN–(Zr,Cr,Al)N coatings, deposited through the technology of the filtered cathodic vacuum arc deposition (FCVAD). The studies included the microstructured investigations using SEM, the analysis of chemical composition (Energy-dispersive X-ray spectroscopy, EDXS), the determination of the value of critical failure force (with the use of scratch testing), and the measurement of the microhardness of the coatings under study. The cutting tests were conducted in end milling of titanium alloys at various cutting speeds. The mechanisms of wear and failure for end milling cutters with the coatings under study were studied in milling. The studies determined the advantages of using a tool with the coatings under study compared to an uncoated tool, as well as to tools with the commercial Ti–TiN coating and the nano-structured Ti–TiN–(Ti,Al)N coating. Adding Cr to the composition of the coating can significantly increase the hardness, while the coating retains sufficient ductility and brittle fracture resistance, which allows for a best result when milling titanium alloys.
Highlights
Titanium alloys are widely used in various fields of modern engineering, in particular in aerospace.In approximately 57% of cases, such parts of gas turbine engines, as blades, rotors of centrifugal compressors, and monowheels are made of titanium alloys [1,2,3]
There are a number of studies considering the effect of various wear mechanisms on cutting tools and ways to further improve the performance in end milling of titanium alloys
In [5], it was found that in end milling of a workpiece made of Ti–6Al–4V titanium alloy with an uncoated carbide tool, the prevailing wear mechanisms on the rake face were adhesive and diffusive wear, while on the flank face, they were adhesive and abrasive wear
Summary
Titanium alloys are widely used in various fields of modern engineering, in particular in aerospace. In approximately 57% of cases, such parts of gas turbine engines, as blades, rotors of centrifugal compressors, and monowheels are made of titanium alloys [1,2,3]. Due to their high strength, toughness, oxidizability, and low thermal conductivity, they are hard-to-cut materials, which leads to considerable difficulties in their machining. There are a number of studies considering the effect of various wear mechanisms on cutting tools and ways to further improve the performance in end milling of titanium alloys. The component of the cutting force Py is dominant, and its change can be used to control the degree of tool wear
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