Coated Carbide Tools Research Articles

Modulation-assisted machining of compacted graphite iron with coated carbide tool in dry condition

Compacted graphite iron (CGI) is a new material replacing conventional gray cast iron (FGI) for diesel engine block applications due to its superior mechanical properties. However, widespread adoption of CGI is hindered by its poor machinability, which is reflected by the rapid tool wear especially at higher cutting speeds. In current industrial practice, CGI is usually machined with coated carbide tools at low to medium speeds (< 200 m/min). This study investigates the effect of modulation-assisted machining (MAM) on tool wear in dry turning of CGI with coated carbide tool. A new MAM turning setup is implemented for conducting the longitudinal turning experiments. Tool wear, cutting forces and tool temperature are characterized for both conventional machining (CM) turning and MAM turning at three cutting speeds: 150, 250 and 350 m/min. The results show wear reduction by MAM is not significant at the low cutting speed (150 m/min), but it is quite significant at the higher cutting speeds (250 and 350 m/min). The cutting force and temperature results can be well correlated with the wear results, revealing the dependency of the forces and temperature on the tool wear and the severity of iron adhesion. This study demonstrates the potential of MAM in enhancing the productivity of machining CGI with the coated carbide tool. The results are also useful for better understanding the wear mechanism in cutting CGI with the coated carbide tool.

Temperature Optimization by Using Response Surface Methodology and Desirability Analysis of Aluminium 6061.

Because aluminium is a lightweight and low-density material, its alloys, such as Al 6061 alloy, are extensively used in numerous automobile, defense, and aviation components. This study aims to develop a predictive model to investigate the impact of tool nose radius on the CNC turning process of Al 6061 alloy and better recognize the implications of operating machining considering cutting speed, rate of feed, cutting depth, and tool nose radius. The trials were carried out by using the response surface methodology (RSM), with an Al2O3 coated carbide tool as the cutter and an Al 6061 workpiece as the material. A mathematical model of the second-order was created. The analysis of variance (ANOVA) approach was used to analyze the performance characteristics of the turning operation. Individual desirability values from the desirability function analysis for the multi-responses are used to construct a composite desirability value. The ideal parameter levels were determined by using the composite desirability value, and the significant impact of parameters was assessed by using the analysis of variance. The minimum temperature attained at the machining parameters are 98.0 m/min cutting speed, 0.26 mm/rev rate of feed, 0.893 mm cutting depth, and 0.84 mm tool nose radius. The best total desirability value is 23.615 °C, indicating that the experimental results are close to the predicted values.

"Tool Optimization for Matrix Composite Turning using Coated and Uncoated Cutting Tools "

Industries usually want to make a profit; this includes everything from materials to equipment to deep-cutting tools to work materials, and one product that fits the bill is metal matrix composite. Due to its low cost, metal matrix composites are increasingly being used more and more in a variety of industries, including aerospace and automotive. However, because of their anisotropic and non-homogeneous structure, as well as the high abrasiveness of their reinforcing elements, metal matrix composite materials are difficult to machine. Even so, these industries are compelled to move with MMC because damage is frequently introduced into the work piece as well as very quick wear development in the cutting tool. When milling MMC, the cutting tool is said to be the most important component. A good cutting tool that doesn't break while milling MMC will undoubtedly produce good results and find widespread application. Although cutting speed has been found to be more efficient, the wear rate of the cutting tool significantly dropped as cutting parameters like feed and depth of cut were increased. High cutting speeds caused tool inserts to break suddenly. Tool life has been greatly increased using coated carbide tools. Compared to uncoated tools, coated tools produce better outcomes. Consequently, this research highlights a crucial feature in areas like optimization and design. Using coated and uncoated tools, Minitab software is used to analyze the tool's break even point during turning operations on Metal matrix composites while comparing the graph of the material removal rate in MMC.

Research on tool wear morphology and mechanism during turning nickel-based alloy GH4169 with PVD-TiAlN coated carbide tool

Tool wear affects tool life, dimensions, etc. However, tool wear mechanism was mainly studied by the relevant references in the sharp wear stage, and tool wear morphology and mechanism were not completely understood in the initial and steady wear stage. Tool wear investigation of coated carbide tool is carried out during turning GH4169 in dry cutting. Tool wear microscopic morphology, tool wear curve, tool cutting force and tool wear mechanism are studied during turning GH4169 in the initial, steady and sharp wear stage. Tool wear mechanism in the sharp wear stage is further investigated by SEM, EDS, XPS and XRD. Doing so helps to test and improve the quality of the tool coating and substrate material, helps to gain a deep understanding of the difficult-to-machine characteristics of GH4169, and helps to guarantee the dimensional accuracy and surface quality of the workpiece. Results show that serious abrasive wear, tool nose wear and adhesive wear occurred in the whole wear stage. The tool wear rate of turning superalloy GH4169 is much faster, the cutting force increases, the tool substrate material was worn seriously. The main tool wear mechanisms are abrasive wear, adhesive wear, oxidation wear and diffusion wear. Severe abrasive wear occurred between the large amount of hard abrasive carbides in the workpiece material and the tool rake and flank faces. Ni, Fe, Cr, etc are mainly distributed in the relevant wear areas. WO3, Co3O4, Ni2O3, Fe2O3, etc indicate that oxidation wear occurred, Ni, Fe, Cr, Nb and Mo are detected across the cross-section, which means that diffusion wear has occurred.

Performance evaluation of AlTiN coated carbide tools during machining of ceramic reinforced Cu-based hybrid composites under cryogenic, pure-minimum quantity lubrication and dry regimes

In this study, the machining performance of 10 wt.% B-Ti-SiCp particles reinforced Cu-based hybrid composites were investigated under dry, minimum quantity lubrication (MQL) and cryogenic LN2 assisted environments during milling. In-depth analyses comprising of tool wear development, surface roughness, surface texture, cutting temperature, cutting energy, and chip morphologies were thoroughly performed. According to the experimental results, MQL environment was found to be most influential method to prevent build-up-edge formation. In addition, LN2 assisted cryogenic coolant medium is the most powerful method in all machining characteristics as providing better tribological properties. The paper proposes a novel approach for improved machinability performance of Cu-based hybrid composites with sustainable techniques.

Comparative performance evaluation between HSN-TiAlxN and TiCN coated carbide tools in hard turning of AISI D6 steel

Hardened steels are exclusively in great demand particularly in mould and die making industries. Cutting tools such as ceramic, CBN, PCBN and PCD are normally preferred to machine hard to cut materials but are expensive in terms of cost. The usage of carbide tools with proper coatings within a particular machining range, a comparable tool life can be achieved with lesser cost in hard machining. The present experimental work dealt with a comparative assessment among newly developed TiAlxN and traditional TiCN coated carbide tools in terms of tool life, tool (crater and flank) wear, cutting temperature and surface integrity in dry hard turning of AISI D6 steel. The experiments with 16 trials are performed according to L16 orthogonal array by considering various machining parameters such as cutting speed, depth of cut and feed. Finally, the measured tool life was considered in the Gilbert’s economic approach, to perform a distinctive cost analysis which justified the cost-effectiveness of coated carbide tool in hard turning. Among the tools used, TiAlxN coated carbide tool for hard turning application promises and excellent machinability performances in terms of (i) lower flank and crater wears (ii) longer tool life, (iii) improved surface integrity, (iv) minimum cutting temperature and (v) considerable economic advantages as the production cost is reduced by 6%. The nanostructured TiAlxN coating accomplished by physical vapour deposition (PVD) technique considerably developed lower range of tool wear (VB = 0.053–0.134 mm), produced surface finish (Ra) within 0.35–1.07 µm, and following the surface quality at par closer to cylindrical grinding because of superior surface hardness, wear resistance, and bonding strength of coating material. TiAlxN coated carbide tool offered significant cost savings (Rs. 82.21 in Indian currency) in production costs in comparison to hard turning via. TiCN (Rs. 87.10) coated insert.

Comparative performance evaluation between uncoated and TiAlN + AlCrN coated carbide tools in hard turning of AISI H11 steel

Cutting tools, such as ceramic, cubic boron nitride, and polycrystalline diamond, are normally preferred to machine hardened hot work steel materials which are exclusively demanded in mould and die-making industries. However, such tool materials are very costly. If carbide tools with proper coatings will be used within a particular machining range, comparative tool life can be achieved with lesser cost in hard machining. The present experimental work is based on the comparative assessment among new generation TiAlN + AlCrN coated and traditional uncoated carbide tools concerning tool life, tool flank wear, cutting temperature, cutting force, and surface integrity in dry hard turning of AISI H11 steel. The experiments with 16 trials are performed according to the L16orthogonal array by considering various machining parameters that include cutting speed, depth of cut, and feed. At last, with the measured tool life and as per Gilbert's economic approach, distinctive cost analysis has been implemented to demonstrate the cost-effectiveness of coated carbide tools in hard turning. From the experimental results, a promising machining performance is noticed for TiAlN + AlCrN coated carbide inserts in terms of all machining attributes compared to uncoated carbide inserts due to superior wear resistance, and surface hardness as well as strength of coating material. In summary, the multilayer TiAlN + AlCrN coated carbide tool offers significant cost savings (Rs. 12.82 in Indian currency), with a 9% reduction in production costs in comparison with hard turning via. uncoated insert (Rs. 14).

Analysis of Cutting Forces and Surface Roughness in Machining Al2219, Unhybrid and Hybrid Metal Matrix Nano Composites using CCD Design of Experiment

Nano Composites (nano MMCs) exhibit outstanding engineering properties like wear resistance, better stiffness, low density, and excellent ratio of strength to weight and so on. Unhybrid and hybrid nano MMC composites were fabricated using liquid metallurgical stir casting technique. Turning of Al2219 through TiN coated carbide tool was carried out to investigate surface roughness and cutting forces, by considering the cutting parameters like feed rate and speed. Response surface methodology (RSM) was used to design the experiments and to analyze the obtained results. The obtained results indicated that the cutting forces and surface roughness increases with increase in feed rate and decreases with increase in cutting speed. RSM displayed model and measured values are truly close to each other, which shows that created model can be effectively used to predict the cutting force and surface roughness on turning of MMCs. The predicted model values and obtained experimental values were close to each other with minimal error of 5 %, so the model is adequate.&#x0D; HIGHLIGHTS&#x0D; &#x0D; Nano Metal Matric Composites reinforced Al2219 with n-B4C &amp; MoS2 particles successfully using stir casting&#x0D; Feed rate is the key influencing factor and the cutting speed had slight influence on cutting force, surface roughness and tool wear&#x0D; The experimental values obtained and predicted modeled values are within 5 % of each other, then the model is adequate&#x0D; &#x0D; GRAPHICAL ABSTRACT

Machining performance and wear mechanism of PVD TiAlN/AlCrN coated carbide tool in precision machining of selective laser melted Ti6Al4V alloys under dry and MQL conditions

Selective laser melting (SLM) shows significant advantages in near net-shaped manufacturing of metal components with complex geometries. However, subsequent post-machining is usually conducted for the improvement of surface quality and dimensional accuracy of SLMed parts. This paper focuses on the precision machining performance of SLMed Ti6Al4V alloys and wear mechanism of multi-layered TiAlN/AlCrN coated carbide tools. The influence of laser scanning schemes, machining surfaces as well as lubrication conditions (dry and MQL) on machinability of SLMed Ti6Al4V alloys in terms of cutting force, surface quality, tool wear morphology and wear mechanism was evaluated and analyzed. The results indicate that, the largest difference in cutting force and surface roughness between the top and front surfaces under dry cutting occurred in 0°-linear SLMed Ti6Al4V alloy due to its prominent anisotropic features. Compared to the surface quality in dry cutting, the improvement of surface roughness of SLMed Ti6Al4V alloys under MQL is up to 82.2%, which was significantly superior to the 59.2% improvement of annealed titanium alloy. Because of the improvement of tribological properties between the flank and machined surface, adhesive wear becomes the primary wear mechanism of TiAlN/AlCrN coated carbide tools under MQL during precision machining of SLMed Ti6Al4V alloys, while abrasive wear is the main wear mechanism under dry cutting. In addition, the ductility and integrity of ribbon chips derived from SLMed Ti6Al4V alloys are superior to those of chips originating from annealed titanium alloy, where significant tearing and cracking occurred in the chips of annealed titanium alloy.

Analysis of surface roughness and energy consumption in turning of C17500 copper alloy under different machining environments and modellings with response surface method

The difficulties in machinability due to the developments in the technical properties of engineering materials increase the importance of machinability indicators such as surface quality, power or energy consumption and tool life in terms of sustainable machining. In this context, the machinability of a copper-beryllium alloy (C17500), which is used in a wide range of industries and also characterized as a hybrid material, was investigated in vortex tube cooling and dry cutting environments. First, turning experiments were performed with a coated carbide tool and varying cutting speed, feed rate and depth of cut. In the experiments, the total energy consumed during turning and the roughness of the machined surfaces were measured, and analysed experimentally and statistically. In the second stage, mathematical models were developed for the total energy consumption and average surface roughness for both cutting environments with the response surface method. As a result, the chip formation process in the turning of the Cu alloy under vortex tube cooling negatively affected the cutting power and positively contributed to the surface quality. Due to the fact that vortex tube cooling creates a cooling effect rather than lubrication, built-up layer/built-up edge (BUL/BUE) formation on the tool cutting edges caused the change in the tool geometry and thus the chip removal process became more difficult and increased the energy consumption. On the other hand, in the vortex tube cooling application, the surface roughness decreased by an average of 31.4% compared to dry cutting. Furthermore, the predictive mathematical models developed for the total energy consumption and the mean surface roughness can be used with high reliability.

Parametric study and multi-criteria optimization during turning of X210Cr12 steel using the desirability function and hybrid Taguchi-WASPAS method

The present study examines the machining of a cold work tool steel (X210Cr12) using a triple chemical vapor deposition coated carbide tool (Al2O3/TiC/TiCN). The paper is focused on an experimental investigation as well as a modeling and optimization of the working cutting parameters in relationship with the studied material. For that, first, a set of experimental tests were built in order to evaluate the effect of cutting parameters (r, Vc, f, and ap) on the output parameters, namely surface roughness (Ra), cutting force (Fz), insert flank wear (Vb), and 3D roughness distribution. In a second step, a Taguchi L16 (4^3 2^1) design of experiment (DoE) was exploited with the aim to develop a modeling of output working parameters based on the response surface methodology. An optimization of the cutting conditions was performed using the desirability function (DF) approach and the hybrid Taguchi-weighted aggregate sum product assessment method. The desired objective is to obtain optimal cutting regime corresponding to the simultaneous minimization of parameters Ra and Fz, and maximization of material removal rate. The results found show that the factor f influences Ra with 42.55% and that parameter ap affects parameters Fz and Pc with 67.55 and 60.88%, respectively. For the DF and WASPAS methods, the optimal regimes selected is r = 1.6 mm, Vc = 366 m/min, ap = 0.17 mm, f = 0.16 mm/rev and r = 1.6 mm, Vc = 180 m/min, ap = 0.3 mm, and f = 0.08 mm/rev, respectively. The proposed work concerns all mechanical manufacturing companies, as it provides the necessary information on the optimal working conditions of the tool/material pair.

Hard turning of AISI D6 steel with recently developed HSN2-TiAlxN and conventional TiCN coated carbide tools: comparative machinability investigation and sustainability assessment

Hard turning of AISI D6 steel with recently developed HSN2-TiAlxN and conventional TiCN coated carbide tools: comparative machinability investigation and sustainability assessment

EXPERIMENTAL INVESTIGATION AND ANALYSIS OF SURFACE ROUGHNESS PARAMETERS IN HARD TURNING OF AISI D2 STEEL USING COATED CARBIDE TOOLS

In the present work, hard turning of AISID2 Steel were carried out on CNC turning centre using TiCN coated carbide tools to investigate the effect of cutting parameters on surface roughness parameters (Ra, Rq, Rz) The statistical models were developed using the Taguchi method to find the effect of cutting parameters (speed, feed, and depth of cut) on surface roughness parameters. L9 orthogonal array is designed for the experiments and experiments were carried out for one, two and three passes to evaluate the optimum roughness value of the surface roughness parameters. It was observed from the results that the feed rate played an important role with surface parameters.

Experimental investigation into machinability of hardened AISI D6 steel using newly developed AlTiSiN coated carbide tools under sustainable finish dry hard turning

In the present study, a newly developed AlTiSiN coating material deposited on carbide insert by scalable pulsed power plasma (SPPP) technique is used for machinability investigation of hardened AISI D6 die steel (65HRC) in finish dry turning. Also, the cutting tool is characterized by various diagnostic tests to evaluate the effectiveness of nanocomposite AlTISiN coating material and its cutting performance. A series of machining trials have been performed under varied cutting conditions (feed, depth of cut, speed) to investigate the machinability concerning surface roughness, flank wear, and chip morphology. Further, an approach towards multi-response optimization and predictive modelling for minimization of flank wear and surface roughness have been performed using response surface methodology. Finally, a unique approach has been proposed for economic analysis and sustainability assessment in hard turning. Result shows that the nanostructured AlTiSiN coating developed lower range of tool wear (VB = 0.044–0.076 mm), produced surface finish (Ra) within 0.322–0.905 µm which is approaching the surface quality to that of cylindrical grinding because of minimum friction coefficient, good bonding capability and enhancement in hardness as well as wear resistance of coating material. Statistical analysis reveals that Ra and VB are influenced principally by feed (84.14%) and cutting speed (53.43%), respectively. With the tool life of 34 min, Gilbert's machining economic model calculated the overall machining cost per part of Rs.61.04 in hard turning using coated carbide insert. Chip morphology confirmed the formation of serrated type saw tooth chips. It is established that machining under dry condition provides environment friendliness, techno-economically feasible to improve sustainability.

Study on wear mechanism of coated carbide tool in turning of pearlitic gray cast iron with Al additives

Study on wear mechanism of coated carbide tool in turning of pearlitic gray cast iron with Al additives

Investigation on tool wear and chip morphology in hard turning of EN 31 steel using AlTiN-PVD coated carbide cutting tool

Hard turning is a well-known machining technology by which a cylindrical job of hardness above 45 HRC is machined using a single point tool. In hard turning, higher tool wear is the main issue identified by the machinist. In the hard turning activity, tool wear is severely stimulus by cutting parameters, cutting tool materials, and cutting environment. The temperature evolved in the cutting process is the prime factor to accelerate the tool wear. However, there is a requirement to control the temperature intensity by selecting suitable input turning parameters and cutting environment. However, the current research emphasizes the selection of suitable input turning parameters and suitable coated carbide tools in hard turning of EN-31 bearing steel of hardness 56 HRC in conventional flood cooling. AlTiN-PVD coated carbide insert was used to execute the turnings tests using Taguchi L16 orthogonal array, and a detailed study on tool wear and chip pattern formation is investigated. AlTiN PVD coated carbide tool performed excellently in flood cooling as maximum tool wear was found as 0.065 mm which is very less for hard turning concerns. Also, long helical and ribbon chips patterns are identified in the entire investigation. Blue color chips are identified at 240 m/min of cutting speed which confirmed the generation of higher cutting temperature in course of cutting. The present findings can be suitable for the industries that are still using a conventional cooling method in the machining of heat-treated steels having hardness 45–69 HRC.

Experimental evaluation onto the machinability of sustainable Al/SiC/Gr hybrid composite using grey relational analysis

The utilization of Aluminium Matrix Composites (AMCs) has undergone a tremendous increase due to its distinct characteristics. However, the inclusion of reinforcement in the aluminium matrix reduces its machinability due to the presence of hard reinforcements in it. This research article refers to the fabrication and evaluation of machining behaviour of newly developed SiC and Graphite reinforced AMC. AMCs were developed through the stir casting route. Al 6061 alloy was selected as the base matrix, which was reinforced with silicon carbide Graphite. Uncoated and multiple layer coated carbide tools were used to evaluate the turning of AMC at various speeds (60, 90 and 120 m/min) and feeds (0.07, 1.0 and 0.13 mm/rev) in the form of surface roughness, material cutting rate and tool wear rate by employing Grey Relational Analysis. Results indicated that feed rate is the highly prominent parameters affecting process performance, followed by spindle speed and tool type. The optimum set of input conditions is to turn Al-SiC-Gr hybrid AMC at a speed of 120 m/min feed of 0.1 mm/rev with a coated carbide tool. The predicted value of Grey Relational Grades was also determined to validate results.

Comparative assessments of machining forces in 3D printed polymer composite during milling operation using two coated carbide end mills

The composites of carbon fiber reinforced polymer (CFRP) are rapidly turning into the most extensively used material in aerospace and automotive applications due to their superior corrosion-resistant exterior and ratio of strength-to-weight. The flexibility to fabricate complex shapes and alter the fiber orientation of CFRP composites via three-dimensional (3D) printing or additive manufacturing is gaining prominence. However, because of their anisotropic and heterogeneous structure these composites were regarded as the difficult-to-cut materials. The parts made out of these composites are often made to near-net shape in astronautic and aerospace industry. However, part finishing typically necessitates post-process machining such as milling, in order to satisfy dimensional accuracy prior to assembly. The aim of this thesis is to explore the machinability aspects in terms of machining forces 3D printed CFRP composites by milling CFRP employing TiAlCrN and hard carbon coated solid carbide end mills in dry cutting environments. A 3D printed multidirectional CFRP workpiece was fabricated using a Mark forged industrial printer and milling operations were carried on additively manufactured workpiece with two distinct coated tools according to the experimental design created on Taguchi’s L16 orthogonal array in which three variables namely feed rate, depth of cut, spindle speed were altered at four distinct levels. With TiAlCrN coated carbide tool, least machining forces observed compared to hard carbon coated carbide tool.

Cutting forces and tool wear studies on machining of Hastelloy X

Hastelloy based nickel materials are hard to cut category due to their properties like high strength during elevated temperature and excellent stress corrosion resistance. The machinability of such alloy is very much essential during fitment meanwhile tool wear need to be considered with utmost care. This study focused on turning operation of Hastelloy X using different cutting tools under dry conditions with different sets of cutting speeds and feeds. The impact of input cutting conditions on tool wear have been investigated experimentally with three different cutting tools. The turning operation was carried out at two different feeds 0.111 & 0.127 mm/rev and three different cutting speeds 23.86, 37.69 & 57.80 m/min with three different tool inserts. The cutting tool inserts involve an uncoated carbide tool and two coated carbide tools with Titanium Aluminium Nitride (TiAlN) coating and Titanium Nitride (TiN) coating. Optical microscopy and machine vision system were employed to analyze the crater and flank wear. The cutting forces were monitored for different conditions with lathe tool dynamometer. TiAlN coated insert shown better response when compared with other two inserts.

Optimization of cutting parameters during CNC milling of EN24 steel with Tungsten carbide coated inserts: A critical review

Recent developments in advanced technology have led to CNC milling machines in many industries to achieve better quality and productivity. The CNC milling machine outperforms traditional machines in precision and surface quality. By optimizing the process parameters, one can fully utilize CNC milling machining. As a result, this paper reviews the optimizing process parameters for CNC milling using Tungsten coated carbide tools. The review shows that the feed, speed, and DOC influence material removal rate, surface roughness, and tool wear. researchers have used Taguchi and RSM for Optimization. Surface and contour graphs to analyze the effect of milling parameters on tool wear, MRR, and surface roughness. For optimization, the response surface methodology (RSM) by approach. The impact of machining parameters on response parameters is analyzed using ANOVA. It was found that there is scope for optimizing the process parameters for the material EN24.