Coated Tungsten Carbide Tools Research Articles

Investigation of parameters and morphology of coated WC tool while machining X-750 using NSGA-II

Nickel-based superalloys have numerous applications in automobile, aerospace, turbine blades, nuclear, oil refinery etc, due to their excellent properties like strength, wear resistance, corrosion resistance and higher creep strength. Because of these properties, modern manufacturing industries need help with the machining of nickel-based superalloys, i.e. hard-to-machine materials. In the present research, Ni-based X-750 alloy is machined with turning operation by a conventional lathe machine using a TiAlN PVD coated tungsten carbide tool at different rotational speed (TRS), depth of cut (DoC) and feed (F) values as input parameters whereas material removal rate (MRR) and tool wear (TW) are the responses of the study. The design of experiments (DoE) is prepared by response surface methodology-based Box-Behnken Design. Analysis of variance (ANOVA) was applied to investigate the percentage contribution of each machining parameter on responses. Non-dominated Sorting Genetic Algorithm-II (NSGA-II) simultaneously optimizes the developed empirical models of MRR and TW. The predicted solutions suggested by NSGA-II are the best solution, and confirmation experiments are conducted on randomly selected parametric settings from these solutions. The optimized set presented by NSGA-II is TRS: 900RPM; DoC: 0.06 mm; F: 0.1 mm rev−1, and the maximum relative error in the case of MRR and TW is in the permissible limit. Scanning electron microscopy (SEM) and Energy dispersive spectroscopy (EDS) are used to investigate the morphology of tool insert before and after machining at optimized value TRS: 900 RPM; DoC: 0.1 mm; F: 0.06 mm rev−1, and it shows the wear marks on the tool, and the Energy dispersive spectroscopy confirms the presence of coating and WC. SEM is used to investigate the morphology of chips formed at different optimized parametric settings.

Optimizing the machining parameters during turning of EN 31 steel using TiN + Al2O3 + TiCN coated tungsten carbide tool

EN31 steel is a high strengthsteel alloy offering good combination of ductility, strength and wear resistance. Achieving optimum material removal rate and surface finish is achallenging task while machining this alloy. The present work involves an experimental investigation to optimize process parameter for turning of EN-31 steel using TiN + Al2O3 + TiCN coated tungsten carbide tool. Three distinctive parameters viz. cutting speed (v), depth of cut (d) and feed rate (f) were selected to carry out the turning operation. The experimental runs are designed using Taguchi’s L9 orthogonal array and are then carried out using a lathe machine tool. Outcome of experimentation witnessed material removal rate (MRR) and surface roughness (SR) as the two critical responses and are analyzed by taking their signal-to-noise (S/N) ratio. ANOVA analysis has employed to determine the most significant parameters. The optimal process setting for MRR and SR are v3d3f3 and v1d1f1 resulting to a higher MRR with the least SR has been verified through conducting a confirmation experiment. Empirical models are also developed to correlate the output response and turning parameters.

Machinability investigation of Chromoly steel using TiN/Al2O3/TiCN/TiOCN multilayer coated tungsten carbide tool inserts with artificial neural network methodology

AbstractEnhancing the machining efficiency of hardened steel using four‐layer coated tungsten carbide tools has gained a lot of interest among manufacturing engineers. This paper reports the machining performance of AISI 4140 steel using TiN/Al2O3/TiCN/TiOCN multilayer coated tungsten carbide tool inserts. The impact of cutting speed, depth of cut, and the nose radius on machining force, tool chip interface temperature, surface roughness, and chip forms was ascertained using full factorial machining experiments and artificial neural network (ANN) methodology. The machining force evaluated using Logistic Sigmoid activation function resulted in the highest root mean square error (RMSE) of 4.076 and regression value of 0.998. The maximum error between the ANN predicted results and experimental results for machining force, cutting temperature and surface roughness was about 2.4%, 5.3%, and 2.07%, respectively. The best architecture for ANN was “3‐6‐4” which had a coefficient of regression value of 0.97. However, in case of chip form, some of the ANN predicted values could not be mapped to ISO standard chip form and hence prediction accuracy of 80% was achieved.

Influences of tribological and mechanical properties of (Ti /Al)N and diamond like carbon coated tungsten carbide tool on machining and dynamic stability in micro milling of Ti6Al4V

In this article, the performances of thin-film PVD coated tools of similar chemical compositions such as TiAlN and TiN, and dissimilar chemical compositions like diamond like carbon (DLC) with respect to Ti6Al4V workpiece have been intended to analyze. The suitability of thin film coated tools for micro milling of Ti6Al4V is assessed by comparing machining responses such as cutting force, surface roughness, burr height, tool wear and dynamic stability. These are correlated with tribological properties of the coating and tool materials, which has not been reported yet for micro milling of Ti6Al4V. The value of coefficient of friction (COF) for coated and uncoated WC surfaces has been evaluated by considering Ti6Al4V as a counter surface. Among all coated and uncoated tools, the DLC coated surface gives the lowest value of COF which is 0.14. Adhesion is found as the major cause of higher COF of TiAlN coated surface (0.47) and TiN coated surface (0.44) as compared to the uncoated tungsten carbide (WC) surface (0.41). Among all the tools, the DLC coated tool manifested the best machining performance reducing percentage of diameter reduction, burr height, surface roughness, and cutting force by 30 %, 35 %, 17.5 % and 22.2 %, respectively, as compared to the uncoated WC Surface. Further, the critical stability limits of the uncoated and coated tools have been evaluated analytically through the dynamic stability analysis. The DLC coated tool exhibited the best dynamic stability performance enhancing the critical stability limit by 17.04 % compared to the uncoated tool.

Quantification of flank and crater wear in turning of AA7075/SiC composite

ABSTRACT The machining of Al alloy/SiC composites is still a challenge, because the hardness of SiC particles is approximately 2700HV, which is much higher than the hardness of most tool materials. Therefore, the tool wears out quickly. This reduces the tool life and increases the surface roughness of the components of the Al alloy/SiC composites. Hence, there is an urgent need to investigate the influence of SiC particles on tool wear during the turning of 7075Al alloy composites and quantification of flank and crater wear in turning of AA7075/SiC Composite. The experimental tests for turning AA7075/15 wt.% (20-40µm) SiC composite, using coated tungsten carbide tools were conducted. Efforts were made to determine how the cutting speed, feed, depth of cut, and nose radius affect the flank and crater wear of carbide inserts, while turning AA7075/15 wt. % SiC. The effect of the AA7075/15 wt. % SiC composite elements, on tool wear were found out. SiC particles may be removed from the AA7075 matrix, or they may remain in matrix, during machining. If the SiC particles are removed, the tool will not be damaged. If SiC particles remained in the matrix, they scratched the tool flank. This results in excessive tool-flank wear. The results showed that flank and crater wear increased sharply with increasing of depth of cut. SiC was the main element responsible for the wear of the inserts. The novelty of this work is that, so far, little research has been conducted on the influence of elements present in AA7075 Al alloy/SiC composite on the wear of carbide inserts. In this work, investigations were conducted on the effects of elements in AA7075/15 wt. % SiC composite on wear of carbide inserts while machining of AA7075/SiC composites. Measures to minimize tool wear have also been reported. Wear of inserts due to presence of SiC particles in AA7075/15 wt. % SiC composite has been considerably reduced by using carbide inserts coated with titanium nitride (TiN).

Machinability analysis in high speed turning of Ti–6Al–4V alloy and investigation of wear mechanism in AlTiN PVD coated tungsten carbide tool

Titanium alloys are one of the most critical and prominently used materials in automotive, aerospace, and biomedical application due to their superior strength to weight ratio. The very property that makes it a suitable material for such applications also makes it challenging to machine. In this study, an attempt has been made to understand the machinability of Ti–6Al–4V titanium alloy at high cutting speeds in turning. A full factorial method and Analysis of Variance (ANOVA) technique were used to conduct 18 different experimental runs and determine the significance of variables that are responsible for the variation in average surface roughness (Ra) and forces. The results show that feed rate is the single most significant factor for Ra, whereas the contribution of feed and depth of cut are more for the forces, followed by cutting speed. Tool life tests were conducted with AlTiN PVD coated tools at three different cutting speeds, and SEM analysis to evaluate the wear mechanism revealed that abrasive wear, notching, and diffusion were predominant which accelerated the wear rate. Although machining studies on Ti6Al4V at low cutting speeds are well established, the novelty of the study is to perform a comprehensive analysis to evaluate the machinability and study wear mechanism using AlTiN coated tungsten carbide tool at high cutting speeds.

Effect of cutting edge geometry change due to tool wear on hole quality in drilling of carbon fiber reinforced plastics using advanced ceramic coated tools

This paper aims to study the evolution of cutting edge geometry due to tool wear and discuss its impact on the hole quality of a carbon fiber reinforced plastic (CFRP) laminate. A drilling experiment was conducted using three types of twist drills: uncoated, BAM (AlMgB14) coated, and (AlCrSi/Ti)N nanocomposite coated tungsten carbide tools. After generating 120 holes, the uncoated drill had the largest cutting edge radius (∼36 µm), while the BAM coated drill had the most extensive flank wear (∼287 µm) among the three drills. This relatively rapid tool wear results in a reduction of average hole size and a considerable variation on the hole profiles. The worn drills with the cutting edge radius greater than 19.3 µm form the fiber pull-outs in not only the 135° plies but also the adjacent 45° and 90° plies from the cutting direction, creating deep void networks. This type of networked fiber pull-out damage was observed with the holes machined by the uncoated and BAM coated drills. The (AlCrSi/Ti)N coated drill, which experienced the least amount of flank wear and the least increase of cutting edge radius, generated consistently sized holes up to 120 holes. However, the relatively sharp (AlCrSi/Ti)N coated tool results in the higher arithmetic roughness average (Ra) and the maximum roughness height (Rz) values than the other tools due to the localized fiber pull-outs and the absence of severe matrix smearing.

PERFORMANCE OF COATED TUNGSTEN CARBIDE IN MILLING COMPOSITE BOARDS

The purpose of this research was to analyze the performance (wear resistance, surface roughness, chip formation, and noise level) of AlCrN, TiN, and TiAlN coated tungsten carbides in cutting composite boards. The composite boards of wood plastic composite, laminated veneer lumber, andorientedstrand board were cut by the coated tungsten carbide tools in a computer numerical control router. The results show that the differences in structure among the composite boards resulted in the difference in clearance wear, chip formation, surface roughness, and noise level phenomenon. The abrasive materials in wood plastic composite generated the highest clearance wear on the coated carbide tools tested. TiAlN coated carbide tool provided better wear resistance, smoother composite boards surfaces, and lower noise levels.

A comparative study on different textured and untextured tools performance in turning process

ABSTRACT In the turning process, surface quality and tool life significantly depend on the surface texture design, tool geometry, process parameters, and cooling environment. Further, cutting velocity (v) and feed rate (f) have a proportional relationship with productivity. In the past, few attempts were made in turning of AISI 304 under cryogenic, dry, and combination of cryo-MQL conditions with conventional (without texture) tools. In the present research work, different microgroove angles 90° (T-1), 45° (T-2), and 60° (T-3) to the main cutting edge of the tool was prepared on the rake face of the PVD coated tungsten carbide tools, and performed experiments on AISI 304 SS under MQL cooling technique at varying ‘v’ and ‘f’ conditions, respectively. Further, experimental results were compared with untextured tools under MQL and wet cooling, respectively. From the results, the T-1 tool with MQL significantly reduced the surface roughness (Ra), tool wear (Vb), and cutting zone temperature (Tt) when compared to the T-2 tool with MQL, T-3 with MQL, untextured tool with MQL, and untextured tool with wet cooling, respectively, at varying ‘v’ and ‘f’ conditions.

Finite element simulation of AISI 1025 and Al6061 specimen with coated and uncoated tools on turning process using deform-3D

This paper describes how to use Deform-3D software to create a turning process model that can be used to simulate the turning on AISI 1025 carbon steel and Al6061 billets in industrial and automotive applications. The Deform-3D Software is used to build a 3D Finite Element turning model. Pre-processing, Simulation, and Post-processing are all modules that can be used to simulate. Tool and workpiece information, as well as appropriate necessary parameters, were taken into account in the software’s Pre Processing module. Simulation was performed at two different rotational speeds for two different materials using with and without titanium nitride coated tungsten carbide tool. After 1000 steps of simulation, results such as damage, effective strain, effective stress, total velocity, total displacement, and Temperature are reported from the Post Processing module. From results, comparative analysis will be carried out on performance characteristics at different rotational speeds. During the turning process, to accurately predict metal removal Deform 3D software is used for finite element simulation.

Tool characteristics for better performance in machining ohns steel using coated tungsten carbide tool inserts

Turning Process is a significant machining process in which TiAlN covered tipped cutting tool inserts additions expel material from the outside of a pivoting round and hollow work piece. Machining of Oil Hardened Non Shrinking (OHNS) Steel is a challenge for production engineers in tool industry. In this examination paper, an investigation on turning OHNS Steel utilizing tungsten carbide instrument additions is made by shifting profundity of cut, feed rate and cutting rate each in turn and keeping other two consistent. The effect on process parameters like surface finish, material removal rate, tool wear, cutting force, thrust force and temperature distribution on tool tip are discussed.

Experimental investigation on the machinability of nodular ductile iron with cubic boron nitride and tungsten carbide inserts

The nodular irons have more ductility which is demanded by mechanical components like crankshaft, cam shaft, bearing cap and clutch housing, offering fatigue resistance for their intended performance. The impact of various process parameters like depth of cut (D), cutting speed (S) and feed (F) on the cutting force of nodular iron was studied and optimized by using the RSM model. The nodular iron was turned at dry condition with two different types of cutting tools, namely CBN and coated tungsten carbide tool (TiCN + Al2O3 + TiN) to evaluate the influence of cutting parameters. The cutting speed employed for these tests are 102,174 and 245 m/min with feed rates of 0.051, 0.102 and 0.143 mm/rev together with the depth of cuts as 0.5, 0.75 and 1 mm. The tungsten carbide coated tool performed well as compared to CBN tool while machining with nodular iron in terms of getting lower cutting force and better surface roughness.

Investigation of the Effects of Cryogenic Treatment Applied on Coated Tungsten Carbide Tools on Machinability of AISI H11 Steel

Bu çalışmada, AISI H11 sıcak iş takım çeliğinin tornalanmasında kriyojenik işlemin kesici takım performansı üzerine etkileri araştırılmıştır. Deneylerde TiAlN+TiN kaplı tungsten karbür takımlar kullanılmıştır. Kesici takımlar üzerine 6 saat süre ile -80 °C’de sığ kriyojenik işlem (SCT6), 6 saat süre ile -196 °C’de derin kriyojenik işlem (DCT6) ve 24 saat süre ile -196 °C’de derin kriyojenik işlem (DCT24) uygulanmıştır. Tornalama deneyleri 0,6 mm kesme derinliği, 0,18 mm/dev ilerleme hızı ve 320, 360, 400 ve 440 m/dak olmak üzere dört farklı kesme hızında gerçekleştirilmiştir. Deneysel sonuçlar kriyojenik işlemin kesici takımın aşınma direncini artırdığını göstermiştir. En düşük kesici takım aşınması ve yüzey pürüzlülüğü değerleri DCT24 takımla elde edilmiştir. Yanak aşınmasında %13-28 oranlarda, yüzey pürüzlülüğünde ise %7-14 oranlarda iyileşmeler gözlenmiştir. Diğer yandan kriyojenik işlemin kesici takımların sertliğinde %4,4-8,7 oranlarda artış sağladığı tespit edilmiştir. En yüksek sertlik artışı da DCT24 takımda meydana gelmiştir.

Experimental and statistical investigation into micro-EDM of Hastelloy-X using PVD diamond coated and AlTiN coated tungsten carbide electrodes

This paper investigates the effectiveness of electrode coating during the micro-electro-discharge machining (micro-EDM) of a nickel-based Hastelloy X (Ni-X) using uncoated, physical vapour deposition (PVD) diamond-coated, and aluminium titanium nitride (AlTiN)-coated tungsten carbide tool electrodes. The Box-Behnken design (BBD) along with response surface methodology (RSM) was used for modelling the effect of different machining parameters, i.e., capacitance, voltage, tool rotational speed, and tool coating on the micro-EDM performance of Ni-X alloy. The micro-EDM performance was evaluated by machining time, tool wear, crater size and surface microhardness. Capacitance and voltage were found to have significant effect on machining time, tool wear and crater sizes. Increasing capacitance and voltage reduced the machining time as well as tool wear however, crater size was increased indicating rougher machined surface at higher capacitance and voltage settings. [Submitted 19 November 2018; Accepted 18 June 2019]

Experimental studies on the effect of LN2 cooling on the machining of tool steel

Cryogenic coolants as cutting fluids are gaining significance as they are eco-friendly, recyclable and moreover they do no longer produce any dangerous effect on the operators. Cryogenic liquid nitrogen at −196 °C has commonly used coolant in cryogenic machining industries. This experimental work was performed by milling action of AISI D2 tool steel tool wherein the lubrication effect caused due to cryogenic coolant (LN2) sprayed as a cutting fluid in comparison to the less moist (Dry) and moist (wet) metal removing operations based on tear and wear of tool and roughness of the surface on the machined component. Experiments have accomplished the usage of TiN coated tungsten carbide tool which has different speed combinations and feed rate combinations. The workpiece roughness of the surface was minimized up to 15–28% for dry metal removing as well as 26–38% over moist metal removing. This is because of LN2 machining offers higher lubrication and cooling effect was the minimization in the temperature behind cutting.

An experimental investigation on the effect of radial rake angle and machining conditions during end milling on wear resistance and residual stress of nimonic 263 alloy

The tribological and mechanical protection offered to end milled nimonic 263 alloy by the Severe Plastic Deformation (SPD) through machining has been undertaken in the current work. The dry milling of Nimonic 263 alloy has been carried out with a TiAlN coated tungsten carbide tool using vertical machining center. In this study, the surfaces of end milled nimonic 263 are analyzed through x-ray Diffraction Line Profile Analysis (XRDLPA) to evaluate the possible transformation on residual stress using measured interplanar distance between two parallel atomic planes. The quantifiable contributions of machining conditions such as tool nomenclature and machining parameters on the provoked beneficial residual stress on the top surface of the machined samples are evaluated. The SPD processed samples through machining have exposed a significant increment in residual stress which leads to increase the hardness and wear resistance compared to the nascent sample. Further, it reveals that the tool nomenclature has a great extent on the wear resistance followed by machining parameter. Additionally, this study has been carried out to obtain significant machining parameter and tool nomenclature which reflects higher wear resistance of Nimonic 263.

Substitution of commercially coated tungsten carbide tools in dry cylindrical turning process by HiPIMS coated niobium carbide cutting inserts

The deposition of a thin film tool coating as wear resistant layer on tungsten carbide (WC) cutting tool material marks the industrial standard for machining of various workpiece materials. Recent developments on alternative cutting materials show the potential of niobium carbide (NbC) for machining of iron-based materials and its use in cutting tool applications. In this study the tool behavior of two NbC substrates, defined as NbC0.88-12Co and NbC1.0-12Ni4Mo4VC respectively, is compared to commercial, submicron grained WC-6Co tool material. The wear performance of uncoated and physical vapor depositioned (PVD) coated cutting tools is analyzed by scanning electron microscope (SEM), electron backscatter diffraction (EBSD) and energy-dispersive x-ray spectroscopy (EDS) during adhesion tests and machining trials of carbon steel C45E. In uncoated condition, NbC1.0-12No4Mo4VC shows an average increase of material removal VW by 3% combined with a lower crater wear depth KT by 32% compared to industrial WC-6Co standard. Although microstructural defects are evident in NbC substrates, a similar tool performance of coated NbC cutting tools attests the successful substitution of WC-6Co cutting tool material for industrial machining processes.

Tungsten carbide micro-tool wear when micro milling UNS S32205 duplex stainless steel

In conventional machining operations, tool wear is an important aspect of machining with many relevant discussions in the literature. However, in the micromachining process, very little is known about tool wear and wear mechanism compared to conventional machining. Some considerations for tool wear from a macro machining point-of-view may not be valid for micromachining processes because of reduced geometry of the tools and the so called size effect, which affects the kinematics of micromachining and chip formation mechanism. A small wear land on a micro-tool can eliminate half of its edges, and could double the size of the shear force at the other edges of the tool. Therefore, it is necessary to discuss the types of wear and their mechanisms for tools used in micromachining to characterize end-of-life criteria. In this sense, the main goal of this work is to analyze the evolution of wear land of a carbide micro-mill tool when cutting UNS S32205 duplex stainless steel. Experiments were performed to produce micro channels using a 3-axis CNC micro milling machine and TiN coated tungsten carbide tools with diameter 0.381 mm. Previous experiments were performed in order to choose the most appropriate cutting conditions for the evaluation of tool wear. The tools were examined before and after each experiment using a scanning electron microscope. The results show that the major forms of wear encountered during machining are nose and flank face wear, with adhesion being the most clearly observed wear mechanism. The wear land as a function of machined length showed similar behavior to macro machining operations with three defined regions of wear. Taylor's tool life equation was obtained and the resultant coefficients are similar to results from literature for macro machining operations.

Investigation of machinability characteristics on EN47 steel for cutting force and tool wear using optimization technique

In this experimental work dry turning process carried out on EN47 spring steel with coated tungsten carbide tool insert with 0.8 mm nose radius are optimized by using statistical technique. Experiments were conducted at three different cutting speeds (625, 796 and 1250 rpm) with three different feed rates (0.046, 0.062 and 0.093 mm/rev) and depth of cuts (0.2, 0.3 and 0.4 mm). Experiments are conducted based on full factorial design (FFD) 33 three factors and three levels. Analysis of variance is used to identify significant factor for each output response. The result reveals that feed rate is the most significant factor influencing on cutting force followed by depth of cut and cutting speed having less significance. Optimum machining condition for cutting force obtained from the statistical technique. Tool wear measurements are performed with optimum condition of Vc = 796 rpm, ap = 0.2 mm, f = 0.046 mm/rev. The minimum tool wear observed as 0.086 mm with 5 min machining. Analysis of tool wear was done by confocal microscope it was observed that tool wear increases with increasing cutting time.

Comparative study of turning process on EN47 spring steel with different nose radii using statistical technique

Spring steel (EN47) samples are machined (turning) using Sandvik make coated tungsten carbide tool insert with different nose radii (0.4 and 0.8mm) in dry condition and the results are compared with each other. Spring steel is widely used in the manufacturing of vehicle components such as crankshaft, knuckle and leaf spring. EN47 spring steel material is relatively low cost compare to other alloy steels. Experiments are conducted based on taguchi L9 technique. Input parameters are cutting speed, feed rate and depth of cut. The corresponding output parameters are cutting force, surface roughness and tool tip temperature have been analyzed. Experimental result reveals that better surface roughness obtained with higher nose radius. ANOVA results confirm that cutting force is influenced by depth of cut (ap), surface roughness is influenced by feed rate (f) and tooltip temperature is influenced by cutting speed (Vc). Chip morphology and machined surface samples are analyzed using scanning electron microscope (SEM).