Uncoated WC Research Articles

An assessment of machining performance of CAPVD-coated carbide tools in face milling of Ti-6Al-4V

The present study aims to extend the life of tungsten carbide (WC) cutting tools utilized in face milling operations of Ti-6Al-4V by applying hard protective coatings developed using the cathodic-arc physical vapor deposition (CAPVD) technique. Box-Behnken design with 15 experimental runs and response surface methodology were used to mathematically model the relationships between input parameters and output responses to determine the optimal cutting parameters resulting in maximum material removal rate and minimum tool wear. Additionally, the performance of uncoated and coated carbide tools was assessed under dry and wet conditions to identify the best machining conditions. Intriguingly, the tool life of an uncoated WC tool in dry conditions was up to threefold more than that in wet conditions. The tool life of the coated tools was 33% to 166% longer than that of their uncoated counterparts. An analysis of their performance revealed an inverse relationship between the amount of Al in the coating and the tool life. The results from sliding wear tests suggest that Al-deficient coatings have a low coefficient of friction. This study sheds light on the effectiveness of CAPVD-coated carbide tools for improving the tool life during face milling of Ti-6Al-4V.

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.

ELECTRODEPOSITION BASED DEVELOPMENT OF Ni–TiN–AlN AND Ni–SiC–Cr COMPOSITE COATINGS FOR TUNGSTEN CARBIDE CUTTING TOOLS

Metal-based functionally graded coatings have proven effectiveness in improving anti-wear properties and surface integrity of the substrates. The use of electrodeposition coating technique, considering the economics and versatility associated with this method, is a preferred technique of depositing metal-based composite coatings. Further, Ni-based composite coatings are proven for anti-wear applications, and addition of various reinforcement for developing functional coatings need to be evaluated for different applications. This study describes the development, analysis, and performance evaluation of Ni–TiN–AlN and Ni–SiC–Cr electrodeposited composite coatings on tungsten carbide (WC) tool substrates, to impart improved anti-wear properties during machining. The composite coatings were deposited and optimized for current density values of the electrodeposition process, which was identified as the most significant parameter in both the cases. The coatings were characterized using scanning electron microscope (SEM), energy dispersive spectroscopy (EDS) and X-ray diffraction (XRD) for microstructural analysis. The results were further analyzed for tribological behavior through microhardness and adhesion strength tests of the deposited coatings, which are significant properties imitating anti-wear characteristics of the substrate. A significant increase of 47% and 36% in microhardness was obtained for Ni–SiC–Cr coated specimen and Ni–TiN–AlN coated specimen, respectively, compared to the uncoated WC substrates, accompanied with a good adhesion strength in both the cases. The microstructural analysis in both the cases revealed an increase in the deposited coating constituents with increasing current density, leading to a denser coating deposition up to the saturation point, and then beginning of coating delamination due to over-saturation with further increase in current density.

Investigation on the machinability of metastable β titanium alloy M28

Oriented to the application of new generation strategic aircraft, M28 (Ti-4Al-5Mo-5 V-6Cr-1Nb) is a novel metastable β titanium alloy with outstanding strength. The research on the machining of such hard-to-machine material remains inadequate. To investigate the machinability of M28, milling experiments were made with the uncoated WC–Co carbide insert. The cutting force and tool life of M28 were compared with those of Ti-6Al-4 V in varying cutting speeds. The tool wear mode was also analyzed. The cutting force of M28 increases with cutting speed significantly, especially in high-speed cutting where it can reach as high as 132% of that of Ti-6Al-4 V. The “transgranular cut” of M28 contributes to the high cutting force. A much shorter tool life in cutting M28, ranging from 0.88% to 13.82% of that of Ti-6Al-4 V, was found in the experiment. Serious edge chipping occurred at the normal cutting speed as the result of stress concentration and abrasion of the secondary \(\alpha\) precipitation. In high-speed cutting, chip adhesion, comb cracks, and tool plastic deformation were found at the edge as the result of the high temperature. In addition, the semi-crater at the worn edge tip was formed by the interaction of high-frequency cutting impact, carbide thermal softening, and diffusion wear. A better understanding of the machinability of M28 is conducive to the improvement in manufacture in the aviation industry.

Characterizing and Analyzing the Tribological Behaviour of Diamond Coated Tungsten Carbide (WC)

In this research work, the deposition of diamond coating was done on the tungsten carbide (WC) substrate utilizing the the thermal Chemical Vapour Deposition (CVD) technique. The carbon precursor used for growing the diamond on the tungsten carbide (WC) substrate material was sugarcane bagasse. The tribological properties of deposited diamond coating were studied examined in this paper. For characterization of the developed coating, Field Emission Scanning Electron Microscope (FESEM), Raman spectroscopy and X-ray diffraction (XRD), were used to characterize the developed diamond coating on the substrate material. These processes were used to confirm the presence of diamond coating on the substrate. For inspecting the hardness of the developed diamond coated and un coated samples, the tests of micro-hardness were also executed. The values of the Vickers hardness for the un-coated and the diamond coated substrates were found to be 964.95 HV to 1457.48 HV respectively. This depicted a rise of 51% in the hardness of the un-coated WC inserts. As per ASTM G-99 standards tribological behaviour of the developed coated substrate was also the scope of this work using a pin-on-disc tribometer. The tribological tests showed improvement in the wear resistance of the diamond coated WC inserts as there was a decrease in the value of wear by 57.84 %. The value of the coefficient of friction (COF) also found to be decreased by 51.48%. This paper presents a combined study of using tribological tests and morphologic study showing the advantages of coating diamond on the tungsten carbide (WC) substrate.

Effect of LN2 and CO2 Coolants in hard turning of AISI 4340 steel using tungsten carbide tool

Recently, Cryogenic cooling has witnessed a significant role in improving efficiency, increasing the quality of machined parts, and developing a techno-economic and eco-friendly acceptable methodology in the machining of components. This study deals with the effect of hardened AISI 4340 steel at 48 HRC against uncoated WC cutting tool analysed through the use of dry, cryogenic liquid nitrogen (Cryo-LN2) and cryogenic liquid carbon dioxide (Cryo-LCO2) cooling environments. The input parameters for this hard turning condition include cutting velocity, feed rate, and depth of cut. A study of the machining performance of cutting temperature, surface roughness, material side flow, flank wear, microhardness, and chips morphology have also been made. The experiment results revealed the effective lowering of the cutting temperature, better surface roughness and reduced flank wear for LCO2 and LN2 coolant by cryogenic cooling against dry cutting condition. Compared to dry and cryogenic LCO2 cutting environments, the machined zone of a cryogenic LN2 exhibited the highest microhardness value. The main reason for this was the decrease in the thermal softening effect. Overall, the performance of the cryogenic LN2 environment condition was effective and efficient in the turning process compared to dry and cryogenic LCO2.

Proposal of a combined experimental-simulation methodology for the evaluation of machining temperature in turning processes

Although it is essential to know the cutting temperature in turning operations, it is very complex to measure it by direct procedures because of the contact tool-workpiece is not accessible. In this research, a methodology consisting of a natural thermocouple, built from the contact tool-workpiece, has been validated. For that, it was necessary to measure the temperature of a reference point on the tool rake face and to probe the results by FEM. Three different materials were experimented getting to a good agreement between the real values of the temperature and those obtained by simulation. Particularly, the range of measurement was defined for the Ti-aluminides machining by uncoated WC inserts. In addition, taking into consideration the correlations obtained between the temperatures of the flank contact tool-workpiece and of the tool rake face and the wearing in the flank, the evolution of this last variable would be known.

Performance evaluation of tool coatings and nanofluid MQL on the micro-machinability of Ti-6Al-4V

Micromilling of difficult-to-machine materials like Ti-6Al-4V alloy suffers from drawbacks such as tool wear and catastrophic tool breakage due to the tiny diameter of the micro tool. Hence, in this paper, an effort has been made to prolong tool life and improve surface quality via hybridization of water and CuO nanofluid-based MQL with PVD coated (AlTiN/TiAlN) and uncoated WC micro end-mill in micromilling of Ti-6Al-4V alloy. The results exhibited minimum surface roughness at lower concentration (0.25 vol%) of CuO nanofluids with AlTiN coated WC tool and diminished tool wear and built-up edge formation at higher concentration (1 vol%) water-based CuO nanofluids. Under various environmental conditions, the average size of the top burr width was determined on both the up and down milling sides. The minimum average burr width of 9.93 μm was obtained in up milling using 0.25 vol% CuO nanofluids condition with AlTiN coated tool. In the case of down milling, the minimum burr width was 10.58 μm when using 0.25 vol% CuO nanofluids with TiAlN coated tool. Furthermore, significant improvements in tool life and surface quality have been observed through the hybridized sustainable environments obtained by the combined utilization of MQL and coated tools.

Optimizing the Machining performance of CNC tools inserts coated with Diamond like Carbon Coatings under the dry cutting environment

In this research work we have coated WC (tungsten carbide) tool inserts with diamond like carbon coatings. The deposition was done using the thermal Chemical Vapour Deposition (CVD) method. We have used bagasse of sugarcane which is an agriculture waste as a carbon precursor for developing the diamond like carbon coatings. Surface finish, cutting temperature and cutting forces of as-developed diamond like carbon coatings on the WC inserts were examined and analyzed in this research work. For confirming the presence of diamond like carbon coatings on the surface of coated tungsten carbide (WC) tool inserts substrate we have used Raman spectroscopy, X-ray diffraction (XRD) and Field Emission Scanning Electron Microscope (Fe-SEM). The increase in the hardness on the developed coated samples were inspected by performing the hardness test on the coated substrates. The average evaluated Vickers Hardness number were found to be 1455.24 HV and 950.65 HV for both coated as well as un-coated samples respectively. This shows 53% rise in the hardness of the un-coated WC inserts.

Properties of boron carbide thin films deposited by pulsed laser deposition

Boron carbide (B4C) is the third hardest material known after diamond or ta-C and cubic boron nitride (c-BN). Due to its super-hardness and, moreover, its stability up to high temperatures and chemical stability against ferrous materials , it is an interesting material for use as wear resistant coatings , particularly in applications where diamond or ta-C films are not possible to use. Super-hard boron carbide coatings were produced using Pulsed Laser Deposition (PLD) and their mechanical properties were investigated in dependence of the laser fluence and the substrate temperature during deposition. While substrate temperature was found to have a significant influence on the hardness of the coatings, the influence of the ablation fluence was insignificant. At all fluences used, the indentation hardness increases from some 31 GPa at room temperature up to 47 GPa at 500 °C. The Young's modulus was measured to be in the range of 470 to 600 GPa. The films show good adhesion on tungsten carbide but a poorer adhesion on cold working steel. The surface quality, however, was poor at film thicknesses sufficient for practical applications due to the incorporation of many droplets. In order to improve this, an approach was made using an alternative boron carbide target the results of which also are presented. The target was produced by depositing a several ten microns thick boron carbide film on a steel substrate using PLD. The films deposited using this target were found to have much less and much smaller droplets. • Boron carbide coatings with up to 47 GPa hardness can be prepared by Pulsed Laser Deposition. • The substrate temperature during deposition is crucial for the resulting film hardness. • Super-hard boron carbide coatings show a decrease in wear rate by a factor of 11 compared to uncoated WC hard metal. • The use of denser and more homogeneous targets provides less droplet incorporation.

Cumulative reduction of friction and size effects in micro milling through proper selection of coating thickness of TiAlN coated tool: Experimental and analytical assessments

It has been shown earlier that abrasion-resistant coatings on cutting tool can reduce tool wear and friction in micro milling and other machining processes. However, due to coating, the edge radius of micro end mill increases, and the influences of size effects become significant. Therefore, proper selection of the coating thickness is crucial to reduce friction and size effects together. In this article, thin-film coating of TiAlN of different thicknesses (0.5, 1, 2 and 3 μm) has been applied on the WC micro end mill using the physical vapour deposition (PVD) method. First, the enhanced tribological performance of TiAlN coating over un-coated WC material has been verified by evaluating the hardness and coefficient of friction values of both the materials. Next, the appropriate coating thickness value has been selected by experimental and analytical assessments of the machinability parameters and stability limit, respectively, in micro milling of P-20 steel. From the cumulative experimental and analytical investigations, TiAlN coated tool having coating thickness ≈ 1 μm has been found to be the appropriate thin film thickness by witnessing improved machinability and stability limit as compared to the uncoated WC tool and TiAlN coated tools of other coating thicknesses.

The Study of Surface Roughness and Tool Wear Analysis in Turning of Aluminum Using Different Advanced Cutting Tools

As the aviation along with automobile industrial units require high finish with precise surface, so the machining process tends to focus about the machined part surface integrity having lower cost with less tool wear. Aluminium and Al-alloys are the most suitable ones due to their peculiar properties for these requirements.. Here the dry turning of pure aluminium has been attempted using advanced tools like uncoated WC, WC + TiN, WC + Ti(C,N) +Al2O3 and PCD by using speed range from 400 to 700 m/min along with variation in feed rate. The highly precised Surtonic S-128 roughness tester was used to measure surface roughness while SEM (Scanning Electron Microscope) was utilised to observe chip shear band formation and tool wear. The Elemental mapping technique was used to analyse adhesion. The different results show that PCD tools are more suitable than other coated tools for the machining of Al.

Adhesion of Inconel 718 on Uncoated Tungsten Carbide Inserts in Interrupted Orthogonal Machining under MQL

Nickel-base super-alloys such as Inconel 718 are used for demanding applications in the industry. Their superior corrosion resistance and mechanical properties, especially under high heat and pressure, make them very attractive for highly stressed components. In contrast, their low thermal conductivity, work hardening tendency and high strength impose challenges for machining. In particular, occurring adhesion of the workpiece material on tungsten carbide (WC) inserts and tools is common hindering their life. In order to counteract this undesirable effect, cutting fluids are usually implemented. However, due to increased awareness of cutting fluids negative impact on the operator’s health and the environment, minimum quantity lubrication (MQL) is getting more attention among researchers and in the industry. In this study, the adhesion on the rake face of uncoated WC inserts under the application of MQL is observed. Inconel 718 workpieces prepared for orthogonal cutting trials are interrupted at variable intervals to allow more access for MQL to reach chip-tool interface. Mechanical load, coefficient of friction, adhesion area and chip-tool contact length on the rake face are investigated. It has been observed that interrupted machining can positively influence adhesion area and chip-tool contact length.

Characterization and Wear Response of Magnetron Sputtered W–B and W–Ti–B Coatings on WC–Co Tools

In this work, α-WB2 and (W,Ti)B2 borides were applied as wear-resistant coatings to commercial WC–Co cutting inserts. Properties of coatings deposited by magnetron sputtering on WC–Co tools were studied. The crystal structure and chemical composition were analyzed. Vickers hardness and surface roughness were determined and wear test in semi-dry conditions was performed. The W–B and W–Ti–B coatings deposited on WC–Co substrate were smooth and very hard. However, titanium alloy W-B films with Vickers hardness of 3630 ± 260 HV0.02 were characterized by lower adhesion to the substrate, influencing the wear mechanism. Turning tests carried out on 304 stainless steel showed that the W–B film caused less wear compared to uncoated insert. Moreover, when W–B coating was applied, flank wear was reduced by 30% compared to uncoated WC–Co insert. Additionally, coating prevented chipping of the edge during cutting under test conditions. The research shows that W–B film deposited by magnetron sputtering has great potential as a coating for cutting tools for difficult-to-cut materials.

Machining Performance of Inconel 718 Under Dry, MQL, and Nanofluid MQL Conditions: Application of Coconut Oil (Base Fluid) and Multi-walled Carbon Nanotubes as Additives

The present work intends to investigate the application potential of coconut oil, as cutting fluid, during metal machining of a nickel-based superalloy. In doing so, machining performance of difficult-to-cut aerospace superalloy Inconel 718 is studied under dry, minimum quantity lubrication (MQL), and nanofluid MQL (NFMQL) using uncoated WC–Co tool, operated at varied cutting speeds. MQL environment is created by supplying air-oil mist in which commercially available coconut oil is used as cutting fluid. On the other hand, nanofluid is prepared by dispersing a specific concentration of multi-walled carbon nanotubes within coconut oil. Machining performance as observed in MQL and NFMQL is compared to that of dry machining. The following machining performance indicators are considered herein: cutting force magnitude, tool-tip temperature, and width of flank wear progression. In addition, studies on dominant modes and mechanisms of cutting tool wear, chip morphology (macro/micro), and surface roughness of the machined work part are also carried out. In the purview of machined surface roughness, it is concluded that NFMQL performs better than dry machining and conventional MQL. Flank wear is witnessed more severe during dry machining than MQL/NFMQL. However, beyond 83 m/min cutting speed, conventional MQL outperforms NFMQL (with 0.2 wt% nano-additives concentration) machining, from the viewpoint of flank wear width.

Effect of TiN, TiAlCN, AlCrN, and AlTiN ceramic coatings on corrosion behavior of tungsten carbide tool

Hard ceramic coatings are widely used for cutting and forming applications because these coatings on the surface of the tools considerably improve the oxidation, wear, and corrosion resistance of the materials. The aim of this study is to investigate the electrochemical corrosion behavior of TiN, TiAlCN, AlCrN, AlTiN, and multi-layered coat of AlTiN on tungsten carbide (WC) at different mediums. Coatings were performed using the cathodic arc evaporation-physical vapor deposition (CAE-PVD) method. The corrosion behaviors of the coated and uncoated WC materials were carried out with potentiodynamic polarization curves which used to calculate the corrosion rate of the tested materials at the pH values of 2, 7, and 10 at the room temperature. The surface morphologies of the uncoated and coated samples were examined by a scanning electron microscopy (SEM) before and after the corrosion testing. The corrosion experiment results indicated that the corrosion rate (114.7 × 10–6 mpy) of TiAlCN coating was much lower than WC substrate material (38.83 mpy) in pH = 7. The highest corrosion rate (1.559 mpy) was obtained for TiN coating, although the corrosion rate (490.8 × 10–9 mpy) of AlCrN coating was lower in pH = 10. The corrosion resistance of AlCrN coating was also the highest, even if in acidic environment.

Experimental investigation on micro-electro discharge machining process using tungsten carbide and titanium nitride-coated micro-tool electrode for machining of Ti-6Al-4V

ABSTRACT Titanium alloy Ti-6Al-4 V is used in numerous applications because of its low weight associated with high strength, excellent resistance to fatigue and creep, good resistivity in corrosive environments, and biocompatibility. The Micro-Electro Discharge Machining (MEDM) is one of the finest non-conventional machining processes used for machining Ti-6Al-4 V. In this research article an attempt has been made to study effect of thin film coating of titanium nitride (TiN) on tungsten carbide (WC) micro-electrode on tool wear rate (TWR), over cut (OC) and depth of machining (Z coordinator) during micro-drilling of Ti-6Al-4 V. A detailed experimental investigation has been carried out with the help of Taguchi’s L9 orthogonal array for understanding the mechanism of the process. The process parameters such as voltage, spindle rotation and capacitance are considered to perceive their effect on TWR, OC and Z coordinator. Uncoated WC and TiN-coated WC micro-tool electrodes has been used during machining Ti-6Al-4 V in order to compare listed responses. The experimental results of TiN-coated micro-electrode showed that TWR decreased by 16.32 %, depth of machining increased by 20.83% and OC reduced by 12% as compared to uncoated WC micro-tool electrode.

Dry, MQL, and Nanofluid MQL Machining of Ti–6Al–4V Using Uncoated WC–Co Insert: Application of Jatropha Oil as Base Cutting Fluid and Graphene Nanoplatelets as Additives

Nanocutting fluids are very popular due to their excellent thermo-physical and tribological properties which provide adequate cooling and lubrication during metal cutting. Conventional dry machining of difficult-to-cut superalloy Ti–6Al–4V faces several challenges. To overcome this, application of cutting fluid is indeed a necessity. However, performance of conventional minimum quantity lubrication (MQL) system, in which air–oil mist is sprayed into cutting zone, is somewhat limited due to inadequate penetration into tool–work and tool–chip interfacial regions, especially at high cutting speeds. MQL performance can further be enhanced by applying nanocutting fluid in which nano-sized additives are dispersed into the base cutting fluid; this is known as nanofluid MQL (NFMQL). In order to take care of several alarming issues related to environmental protection and occupational health hazards, the present study explores application feasibility of biodegradable Jatropha oil added with graphene nanoplatelets as nanocutting fluid. Machinability of Ti–6Al–4V is assessed under NFMQL; results are compared to that of dry and conventional MQL machining. Cutting force magnitude, tool-tip temperature, morphology of worn-out insert, chip’s macro/micro-morphology and surface roughness of the machined work part, etc., are studied in detail. For MQL and NFMQL, tool wear morphology detects existence of ‘unaffected zones’ which indicates sustenance of strong hydrodynamic tribo-film of cutting fluid, thus protecting the insert against wear. Up to 82 m/min cutting speed, NFMQL causes lower tool flank wear than dry and conventional MQL. On the other hand, superior machined surface finish is obtained under NFMQL up to 106 m/min cutting speed.

Dry turning performance of TiN–WSx/TiN hard-lubricious bilayer composite coating

Dry machining is receiving immense attention worldwide to eliminate or minimize the harmful environmental effects of cutting fluids. The present work investigates dry machining performance of a bilayer coating with top-layer of hard-lubricious TiN–WSx, supported by a hard TiN under layer. During dry turning of AISI 1060 steel, the bilayer coated carbide tool registered significantly less cutting forces as compared to its TiN coated counterpart in the cutting velocity range of 77–230 m/min. In prolonged turning test at cutting velocity of 200 m/min, it also exhibited notably higher tool life on the order of 13 and 2.17 times respectively as compared to the uncoated WC and monolayer TiN coated tool. Such improved performance of bilayer coating was found to be associated with its microstructure, mechanical and tribological properties. Existence of lubricious WS2 phase in the composite TiN–WSx layer along with superior coating adhesion and equivalent nanohardness as compared to TiN resulted in low cutting forces. Formation of W–O tribo layer on surface of worn-out coating on flank surface of tool aided in improving tool life during prolonged turning test.

Coolant boiling and cavitation wear – a new tool wear mechanism on WC tools in machining Alloy 718 with high-pressure coolant

In recent years, research interest in liquid coolant media applied to the tool–workpiece interface (the tertiary shear zone) has grown considerably. In particular, attention has increased for work where the media has been applied under high-pressure. This is most likely triggered by the positive results reported on similar applications, but with coolant media directed towards the rake face of the cutting tool (the secondary shear zone). The most typical applications have not surprisingly been related to the machining of Heat Resistant Super Alloys (HRSA) or other “difficult to machine” alloys where the main intention has been to extend tool life and improve surface finish through reduced shear zone temperatures.Concurrently, these achievements have revealed a knowledge gap and unlocked a new research area in understanding the effects and influences of coolant media applied on super-heated surfaces under high-pressure conditions. The aim of this study is to investigate the “coolant boiling and cavitation” phenomena that emerges during the application of coolant under high-pressure to the flank face of an uncoated WC tool while turning Alloy 718. The experimental campaign was conducted in three aspects: varying flank (coolant media) pressure; varying spiral cutting length (SCL); and varying cutting speed.The results revealed that the location and size of the coolant-boiling region correlated with flank wear, coolant pressure and vapour pressure of the coolant at the investigated pressure levels. Further, the results showed that coolant applied with a lower pressure than the vapour pressure of the coolant itself caused the “Leidenfrost” effect. This then acts as a coolant media barrier and effectively reduces the heat transport from the cutting zone.Further, erosion pits were observed on small areas of the cutting tool, resembling the typical signs of cavitation (usually found in much different applications such as pumps and propellers). The discovered wear mechanism denoted as “Cavitation Wear” was used as base for the discussion aimed to deepen the understanding of the conditions close to the sliding interface between the tool and the workpiece. Even though “Cavitation Wear” has been widely reported in hydraulic systems like pumps and water turbines, it is a new phenomenon to be seen on cutting tools while using high-pressure flank cooling.