Abstract
Experimental data has shown that calcium containing resulphurised free machining austenitic stainless steel has much better machinability than resulphurised free machining austenitic stainless steel, especially in terms of tool life. A thick adhering layer has been found on the rake and flank faces of a WCTiCCo cutting tool when machining calcium containing resulphurised austenitic stainless steel. The mechanism by which this layer is formed and the effect of this layer on tool life is discussed. The adhering layer has been characterised in terms of composition, thickness and shape using scanning electron microscopy and energy-dispersive X-ray analysis. A theory for adhering layer formation is presented in which layer formation is described in four stages: (1) Extrusion of viscous non-metallic inclusions onto the tool surfaces; (2) Adhesion of the coating on the tool; (3) Hardening and growth in thickness of the coating; and (4) Formation of a stable adhered layer.
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