Abstract
Over the past decade, the focus of the metal cutting industry has been on the improvement of tool life for achieving higher productivity and better finish. Researchers are attempting to reduce tool failure in several ways such as modified coating characteristics of a cutting tool, conventional coolant, cryogenic coolant, and cryogenic treated insert. In this study, a single layer coating was made on cutting carbide inserts with newly determined thickness. Coating thickness, presence of coating materials, and coated insert hardness were observed. This investigation also dealt with the effect of machining parameters on the cutting force, surface finish, and tool wear when turning Ti-6Al-4V alloy without coating and Physical Vapor Deposition (PVD)-AlCrN coated carbide cutting inserts under cryogenic conditions. The experimental results showed that AlCrN-based coated tools with cryogenic conditions developed reduced tool wear and surface roughness on the machined surface, and cutting force reductions were observed when a comparison was made with the uncoated carbide insert. The best optimal parameters of a cutting speed (Vc) of 215 m/min, feed rate (f) of 0.102 mm/rev, and depth of cut (doc) of 0.5 mm are recommended for turning titanium alloy using the multi-response TOPSIS technique.
Highlights
IntroductionTitanium alloys are noted as being tough to machine at cutting velocities higher than 30–60 m/min using high-speed steel and tungsten carbide(WC) insert tools, as they induce increased tool wear and poor workpiece surface during machining
Titanium alloys find extensive use in the field of engineering, namely, in biomedical, marine, automotive, aerospace, and petroleum refining components due to the fact of their excellent properties.Titanium alloys are noted as being tough to machine at cutting velocities higher than 30–60 m/min using high-speed steel and tungsten carbide(WC) insert tools, as they induce increased tool wear and poor workpiece surface during machining
The results showed the effectiveness of the deep cryogenic process, with the Physical Vapor Deposition (PVD)-TiAlN carbide insert showing a relevant scaling down in the cutting force by 17% compared with the uncoated insert
Summary
Titanium alloys are noted as being tough to machine at cutting velocities higher than 30–60 m/min using high-speed steel and tungsten carbide(WC) insert tools, as they induce increased tool wear and poor workpiece surface during machining. Titanium alloys show poor machinability due to the fact of their low heat conductivity and low elastic modulus and high reactivity, strength, and hardness at the cutting zone [1]. To address problems of poor machinability, the use of coated cutting tools have been found to be essential. At present, coating represents an important aspect in the development of cutting tool technology. The coated tool can be used in high-speed machining and dry machining. The proper coating can enhance tool life enormously and increase productivity with a reduction in machining cost
Sign-in/Register to view highlights & summary Sign-in/Register to access full text options 
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a call
