Abstract
Coated carbide inserts are considered vital components in machining processes and advanced functional surface integrity of inserts and their coating are decisive factors for tool life. Atomic Force Microscopy (AFM) implementation has gained acceptance over a wide spectrum of research and science applications. When used in a proper systematic manner, the AFM features can be a valuable tool for assessment of tool surface integrity. The aim of this paper is to assess the integrity of coated and uncoated carbide inserts using AFM analytical parameters. Surface morphology of as-received coated and uncoated carbide inserts is examined, analyzed, and characterized through the determination of the appropriate scanning setting, the suitable data type imaging techniques and the most representative data analysis parameters using the MultiMode AFM microscope in contact mode. The results indicate that it is preferable to start with a wider scan size in order to get more accurate interpretation of surface topography. Results are found credible to support the idea that AFM can be used efficiently in detecting flaws and defects of coated and uncoated carbide inserts using specific features such as “Roughness” and “Section” parameters. A recommended strategy is provided for surface examination procedures of cutting inserts using various AFM controlling parameters.
Highlights
The cutting edge is a critical component in machining system elements: tool, workpiece and machine tool
Wear and life variability may lead to disastrous consequences especially in automated and adaptive control machining systems [2] where the machinability information provided by the manufacturer is usually taken for granted
The main aim of this paper is to study and discuss the integrity of coated and uncoated carbide inserts using Atomic Force Microscope (AFM) analytical parameters
Summary
The cutting edge is a critical component in machining system elements: tool, workpiece and machine tool. Variability in tool wear and tool life is one of the unresolved nuisance obstacles to achieve a full optimization of the machining process. Among many other reasons [1], the manufacturing defects on the surface of the inserts can be a major source of tool wear and life variability. Wear and life variability may lead to disastrous consequences especially in automated and adaptive control machining systems [2] where the machinability information provided by the manufacturer is usually taken for granted. A pre-examination of the inserts is, a beneficial strategy especially when the amount of time and money consumed are justified. On an economical and feasibility justified basis, this can be carried out either within the manufacturer quality control or in the research labs’ procedures
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