WC Tool Research Articles

Investigations on laser-assisted turning of IN625 alloy with hot hardness approach using uncoated and CrAlSiN coated WC tools

This paper presents an investigation into the effect of laser-assisted turning of the IN625 superalloy using uncoated and CrAlSiN nanocomposite-coated tungsten carbide tools. A hot hardness test was conducted for IN625 material, which showed there was a pronounced softening of the material above 850 °C. This exercise guided the choice of laser power for the subsequent laser-assisted turning experiments. The cutting forces (radial/thrust, Fx; axial/feed, Fy; and tangential/cutting, Fz), maximum flank wear (VBBmax), and surface roughness ( Ra) were measured and analyzed for the planned experiments. The results demonstrated that at 2500 W laser power, a 9%, 70%, and 59% reduction of cutting forces for uncoated tools, and a 31%, 77%, and 69% reduction for CrAlSiN coated tools were observed in the Fx, Fy, and Fz directions respectively. At 2250 W laser power, the uncoated tools exhibited a 33% (433–289 µm) reduction in VBBmax and a 28% (1.8–1.3 µm) reduction in Ra. The CrAlSiN-coated tools, at 2500 W laser power, showed even more significant improvements, with reductions of 46% (365–232 µm) in VBBmax and 56% (1.4–0.8 µm) in Ra. The results underline the improved performance of laser-assisted turning for cutting-force and tool-wear reduction and improved surface finish with CrAlSiN-coated tools. This paper presents the potential of laser-assisted machining as a viable method for machining difficult-to-machine materials like IN625, which offers enormous manufacturing productivity and tool life benefits.

Friction stir welding of 2507 super-duplex stainless steel: feasibility of butt joint groove filling at different process parameters

ABSTRACT The present work explores the feasibility of groove-filling welding of 6 mm-thick 2507 super-duplex stainless steel (SDSS) in a similar butt-joint configuration using friction stir welding (FSW). A 60° V-groove with a 3 mm root face was designed and machined. The FSW trials were performed at varying rotation speeds (400–600 rpm), downward forces (15–25 kN), and a constant travel speed of 25 mm/min using two WC tools with two different cobalt (Co) contents of 8 and 10 wt.%. The groove filling achievements of the welded joints were monitored using three non-destructive tests: visual, penetrant, and radiographic. All the welded joints were subjected to transverse tensile testing in addition to hardness measurements across the joint area. Microstructure and fracture surface characterisation were also investigated to gain insights into the impact of heat input on joint performance through a comparison with the as-received SDSS. Among the trial FSW processes, the results indicate that the FSW parameters of 25 mm/min, 15 kN, and 400 rpm using a WC-8 wt.% Co tool were successfully used to completely fill the groove and produce a defect-free SDSS butt-joint. This joint has the highest average stir zone (SZ) hardness (342 ± 5 HV) and tensile strength (1256 ± 21 MPa) compared to partially jointed specimens.

Compressive residual stress applied to a low-carbon steel surface alloyed with WC tool constituent elements according to friction stir processing

Friction stir processing (FSP) effectively improves the fatigue strength of arc-welded joints; however, wear of tools is inevitable in case of high-strength materials. Notably, a new benefit has been discovered: compressive residual stress is applied on the FSPed steel surface, alloyed with the WC tool constituent elements, contrasting with the tensile residual stress typically applied via conventional FSP. To elucidate the mechanism of compressive residual stress application, FSP was performed on a low-carbon steel plate at various rotational speeds. The alloyed topmost layers in the stir zone comprised martensite structures with a small amount of retained austenite grains, resulting in a hardness increase owing to the tool constituent elements. The residual stresses on the stir zone surface were influenced by the alloying contents and the corresponding martensite start temperature (Ms). Compressive residual stresses were maximized at an Ms of approximately 150 °C owing to martensitic transformation expansion near room temperature. Lowering the Ms below approximately 150 °C led to tensile residual stresses and an increased volume fraction of the retained austenite, suggesting that martensitic transformation expansion is insufficient to apply compressive residual stress. Conversely, the retained austenite can resist plastic deformation and crack propagation through deformation-induced martensitic transformation, thereby enhancing fatigue properties.

An Investigation of the Effect of Novel Mono/Bi-Layered PVD-Coated WC Tools on the Machinability of Ti-5Al-5V-5Mo-3Cr.

The Ti-5Al-5V-5Mo-3Cr (Ti-5553) alloy is a relatively novel difficult-to-cut material with limited machinability and tool life analysis available in the literature, and hence requires further investigation. This study focuses on the machining and tribological performance of Ti-5553 under high-speed finish turning (150 m/min, 175 m/min, and 200 m/min) via novel mono/bi-layered PVD-coated WC tools. A base AlTiN coating is used as the reference monolayer coating, with AlCrN, diamond-like ta-C, and TiAlSiN coatings each deposited on top of a base AlTiN coating, totaling four separate coated tools (one monolayer and three bi-layer). Tool life, cutting forces, workpiece surface quality, and tribological chip analysis are among the subjects of investigation in this study. Overall, the AlTiN/AlCrN coated tool outperformed all the other combinations: an improvement of ~19% in terms of tool life in reference to the base AlTiN coating when averaging across the three speeds; lowest surface roughness values: ~0.30, 0.33, and 0.64 µm; as well as the lowest chip back surface roughness values: ~0.80, 0.68, and 0.81 µm at 150, 175, and 200 m/min, respectively. These results indicate that the AlTiN/AlCrN coating is an excellent candidate for industrial applications involving high-speed machining of Ti-5553.

Wear and micromechanical performance of novel mono/bi-layered PVD-coated WC tools in high-speed turning of Ti-5Al-5V-5Mo-3Cr alloy

Wear and micromechanical performance of novel mono/bi-layered PVD-coated WC tools in high-speed turning of Ti-5Al-5V-5Mo-3Cr alloy

Optimization of cutting force during turning of custom 450 steel using TiAlSiN coated WC tool inserts

Optimization of cutting force during turning of custom 450 steel using TiAlSiN coated WC tool inserts

Machining Performance Analysis of Ti6-Al-4V in Powder-Mixed EDM Using Green Dielectric Oil

In this investigation, the factors were oil type ([Formula: see text]), powder type ([Formula: see text]), and powder concentration ([Formula: see text]) level, and the machining parameters were the voltage (V), capacitance (pf), pulse-on time ([Formula: see text]), and pulse-off time ([Formula: see text]). The output parameters were the material removal rate (MRR), and tool wear rate (TWR). Three types of oils and powders, along with their respective particle concentrations, were selected for this experiment. Neem, Karanja, and sesame oils were mixed with aluminum oxide (Al2O3), chromium (Cr), and nickel (Ni) powder at 4, 6, and 8[Formula: see text]gm/l, respectively, using an overhead stirrer to investigate the conditions under which the green oil powder mixed mixture yielded a higher MRR and lower TWR during the micro-EDM process of titanium alloy (Ti-6Al-4V) using a 0.8[Formula: see text]mm tungsten carbide (WC) tool with fixed machining parameters (240[Formula: see text]V, 100[Formula: see text]pf, 20[Formula: see text][Formula: see text]s [Formula: see text], and 5[Formula: see text][Formula: see text]s [Formula: see text]). All the powders used in this experiment had a 32-micron (450 mesh) size. The Taguchi L[Formula: see text] orthogonal array and grey relational analysis methods were used to design and optimize the input process parameters for both responses. SEM, optical microscopic analysis, and EDS analysis were performed to examine the surface morphology, characteristics of the WC tool, and elemental composition of both the tool and the workpiece material. The optimum conditions for Karanja oil with a Cr powder mixture concentration of 4[Formula: see text]g/l resulted in higher MRR and lower TWR. However, machining with neem and sesame oils resulted in higher TWR and lower MRR.

Multi-Objective Optimization and Prediction of Responses Using GRA and ANN in Micro-EDM of Ti6Al4V Using Different Tool Materials

An experimental investigation was conducted to evaluate the machinability of a titanium alloy (Ti6Al4V) using copper (Cu), tungsten carbide (WC), and graphite (C) tools. Voltage (V), capacitance (pF), pulse-on time (Ton), and pulse-off time (Toff) were considered as the input machining parameters, whereas the material removal rate (MRR) and tool wear rate (TWR) were considered as the output machining parameters. A Taguchi L[Formula: see text] orthogonal array and gray relational analysis (GRA) were utilized to design and optimize the machining parameters for both responses. Artificial neural network (ANN) analysis was performed to predict the experimental outcomes. Scanning electron microscopy (SEM) and energy-dispersive spectroscopy (EDS) were used to assess the surface morphology and determine the elemental composition of the machined surface. The results indicated that the optimum machining conditions for the copper tool were 150 V, 1000 pF, 15[Formula: see text]s (Ton), and 15[Formula: see text]s (Toff). However, the optimal machining conditions for the WC were 200 V, 100 pF, 25 [Formula: see text]s (Ton), and 10[Formula: see text]s (Toff), and the optimal conditions for the C were 200 V, 1000 pF, 20[Formula: see text]s (Ton), and 25[Formula: see text]s (Toff), respectively. The highest MRR achieved using the WC tool was 9.4510 mg/s, whereas the TWR of the Cu, WC, and C tools were 1.1039 mg/s, 1.0307 mg/s, and 1.2796 mg/s, respectively. The results showed that machining with the graphite tool had a higher TWR than machining with the Cu and WC tools.

Special Issue on Abrasive Technology for High-Precision and High-Efficiency Machining of High-Performance Materials

The demand for high-precision and high-efficient machining of high-performance materials and components has increased in various industries such as optical, automotive, communication, life sciences, and medical sciences. Certain difficult-to-machine materials can be reliably machined using deterministic precision cutting processes. However, hard and brittle materials such as ceramics, carbides, hardened steel molds, glassy materials, or semiconductor materials, require precision abrasive technologies with super abrasives like diamond, cBN, or new tool materials for machining. However, machining high-precision components and their molds/dies using abrasive processes is considerably more difficult due to their complex and non-deterministic nature and textured surfaces. Furthermore, high-energy processes such as laser technology can assist abrasive technologies in ensuring higher precision and efficiency. Precision grinding and polishing processes are primarily used to generate high-quality and functional components, typically made of difficult-to-machine materials. Thus, the surface quality achievable by precision grinding and polishing processes becomes more important for reducing machining time and costs. This special issue features 10 papers on the most recent advances in precision abrasive technologies. These papers cover the following topics: - Ultrasonic grinding of micro holes using cemented WC tools - Drilling holes in CFRP aircraft using cBN electroplated ball end mill - In situ evaluation of drill wear using tool images - Grinding belt based on modified information entropy - Radial directional vibration-assisted grinding of Al2O3 ceramics - Chatter vibration suppression using fixed superabrasive polishing stone - Free abrasive finishing of internal channels with different cross-sectional geometries - High-quality machining of cemented carbide using PCD ball end mills - Fixed-abrasive machining with magnetic brush for Ti-6Al-4V ELI alloy - High-efficient polishing of polymer surfaces using catalyst-referred etching This issue will provide an understanding of the recent developments in abrasive technologies, leading to further research. We deeply appreciate the careful work of all the authors, and we thank the reviewers for their incisive efforts.

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.

Drilling of Ti Grade‐2 Alloy Using WC Tool in Micro‐EDM and Its Multiparameter Optimization

In this study, microelectrical discharge machining (μEDM) is used for drilling microholes on a thin sheet of Ti Grade 2 alloy of thickness 50 μm using a tungsten carbide (WC) microtool of diameter 470 μm. The main focus of the study is to understand the electrical and nonelectrical μEDM parameters on the accuracy, precision, and machining efficiency of drilled holes. The controllable process factors such as capacitance, voltage, tool rotation, and feed rate are considered when conducting the experiments based on a Taguchi L16 orthogonal array. The main effect and interaction contour plots have been prepared to investigate the influence of the process parameters on the response measures like material removal rate, overcut, circularity, and taper angle of the drilled holes. Analysis of variance (ANOVA) has been carried out to study the percentage contribution and significance of each process parameter on the performance measures. The micrographic images reveal the quality of the profiles and edges of the drilled holes. Further, the Overall Evaluation Criterion (OEC) is applied for multiparameter optimization.

Performance evaluation of WC, SiAlON and SiCw + Al2O3 tools in dry machining of Inconel 617

Despite the fact that Inconel 617 has prominent industrial applications, the machining characteristics of the same alloy are relatively unknown. The present study, therefore, aims at comparative evaluation of performance of WC, SiAlON and SiCw + Al2O3 tools under different cutting parameters during dry machining of Inconel 617. Solid solution strengthening due to Ni-Cr-Mo-Co phases and precipitation strengthening due to M23C6 carbide present in Inconel 617 specifically lead to rapid rate of tool wear. Finite element (FE) simulation is carried out to predict cutting zone temperature and tool wear followed by experimental validation. The results indicate that WC tool performs well in terms of cutting force, temperature and surface roughness under the condition of low cutting speed of 50 m/min due to low tool wear. The effectiveness of WC tool rapidly deteriorates under high cutting speeds of 150 and 250 m/min. Ceramic tools outperform WC under the condition of higher cutting speeds in terms of greater resistance to crater and flank wear, cutting force, temperature and surface roughness. However, depth-of-cut notch and nose chipping are the predominant modes of tool wear for ceramic tools during machining of Inconel 617.

Review on high-pressure spark plasma sintering and simulation of the impact of die/punch material combinations on the sample temperature homogeneity

This paper provides a thorough review on high-pressure spark plasma sintering (HP-SPS) experiments conducted to date, with a focus on different tooling materials and their impact on microstructural, mechanical and optical properties of the resulting materials. Any SPS experiment conducted with a pressure over 200 MPa was considered as “high-pressure”. This review was supported by a comprehensive finite-element modelling study of the temperature distribution in the sample and tool set-up as a function of the used geometries, tooling material combinations, temperature window and sample material properties. The effect of the electrical and thermal conductivities of the tool and sample material on the temperature gradients in some specific sample-tool material combinations was elucidated. Electrically and thermally conductive samples in combination with SiC tools showed the lowest temperature gradients during processing, whereas electrical insulators in combination with high pressure WC, steel or TZM tools with an inner graphite die showed the smallest temperature gradients over the sample.

Wear behavior of AlTiN coated WC tools in micromilling of Ti6Al4V alloy using vegetable oil-based nanofluids

The performance of AlTiN coated WC tool with pure vegetable oil-based MQL, vegetable oil with mono (CuO, MoS2), and hybrid (CuO + MoS2) nanofluid-based MQL in micro-milling of Ti6Al4V is investigated, and compared with the dry condition. Viscosity, wettability, and coefficient of friction (COF) of pure soybean oil and mono and hybrid nanofluids are characterized. CuO nanofluid-based MQL exhibited the best result in the shearing-dominant region by reducing tool wear in terms of % diameter reduction, equivalent burr width, and specific cutting force by 68.98%, 37.55%, and 51.40%, respectively, compared to dry conditions, due to the best wetting nature and rolling action. In the plowing-dominant region, the performance of nanofluid-based MQL was not satisfactory owing to the entrapment of the nanoparticles underneath the tool.

Multi-objective optimization based on machine learning and non-dominated sorting genetic algorithm for surface roughness and tool wear in Ti6Al4V turning

Titanium alloys are notoriously difficult to machine. They are used in the manufacture of various types of lightweight components. It is therefore important to improve their machinability and thus achieve sustainability in machining such alloys, by selecting appropriate influential factors: cutting parameters, tool material, geometric form, coolant types, and hybrid machining methods, to deliver efficient output. Nowadays, meta-heuristic algorithms effectively solve multi-objective optimization in machining problems instead of single-objective one. Along with that, the mathematical predictive models used for single-objective optimization are gradually being replaced by machine learning algorithms, which are highly robust and efficient in terms of prediction performance. Therefore, this work addresses the prediction and optimization of average surface roughness (Ra) and tool wear (VB) in Ti6Al4V alloy turning, using a WC tool coated by chemical vapor deposition (CVD) and physical vapor deposition (PVD), with dry machining. We apply a two-pronged approach combining machine learning (ML) and Non-Dominated Sorting Genetic Algorithm (NSGA-II), to model and optimize Ra and VB. The four ML models – Linear Regression (LIN), Support Vector Machine Regression (SVR), Extreme Gradient Boosting (XGB), and Artificial Neural Network (ANN) – are used to predict Ra and VB. The input variables of the turning process – feed rate, depth of cut, cutting speed, cutting time, and tool materials – are the major factors affecting surface quality and tool wear. By the error metrics such as root mean squared error (RMSE), mean absolute error (MAE), and coefficient of determination (R2), ANN is found to offer the best predictive performance. An ML and NSGA-II-based approach is then employed for multi-objective optimization of cutting parameters in Ti6Al4V turning. Fifty Pareto solutions are identified in the range of Ra and VB between (1.332 and 1.441 µm) and (0.100 and 0.125 mm), respectively. In this work, the Pareto solutions are selected based on their ranked performances. This aligns with the decision criterion employed to select the most robust cutting parameters. The definitive optimal Ra and VB are obtained by formulating a robust decisive multi-criterion function which integrates performance, preferred decision criterion, and trustworthiness. Finally, this produces the optimal solution for Ra and VB − 1.439 µm and 0.100 mm, respectively. Experimental validation confirms that the final optimum solution is within the acceptable range.

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.

Sustainable Dry Machining of Stainless Steel with Microwave-Treated Tungsten Carbide Cutting Tools.

This paper presents a research investigation conducted on the turning of stainless steel 316 material under a dry environment using microwave-treated cutting tool inserts. Plain tungsten carbide WC tool inserts were exposed to microwave treatment for enhancement of their performance characteristics. It was found that a 20-min microwave treatment resulted in the best tool hardness and metallurgical characteristics. These tool inserts have been used to machine SS 316 material following the Taguchi L9 design of experimental techniques. A total of eighteen experiments have been conducted by varying three main machining parameters, i.e., cutting speed, feed rate, and depth of cut, at three levels per parameter. It has been found that tool flank wear increased with all three parameters and surface roughness decreased. At the longest dept of cut, surface roughness increased. An abrasion wear mechanism was found on the tool flank face at a high machining speed and adhesion at low speed. Chips with a helical shape and low serrations have been investigated. Turning SS 316 at optimum machining parameters of 170 m/min cutting speed, 0.2 mm/rev feed rate, and 1 mm depth of cut, as obtained by the multiperformance optimization technique grey relational analysis, resulted in the best values of all machinability indicators: 242.21 µm tool flank wear, 3.81 µm mean roughness depth, and 34,000 mm3/min material removal rate, at a single parameter setting. In terms of research achievements, the percentage reduction in surface roughness is approximately 30% and represents an almost ten-fold improvement in the material removal rate. The combination of machining parameters of 70 m/min cutting speed, 0.1 mm/rev feed rate, and 0.5 mm depth of cut is optimum for the lowest value of tool flank wear when considered for single parameter optimization.

Effect of copper, tungsten copper and tungsten carbide tools on micro-electric discharge drilling of Ti–6Al–4V alloy

Achieving microholes with dimensionally higher accuracy on the Ti-6Al-4V alloy using traditional machining techniques is challenging. Micro-electric discharge drilling (μEDD) has become a prominent machining technique in fabricating microholes. Though there are extensive applications of μEDD in producing microholes in difficult-to-cut materials, the appropriate tool materials and process parameters determine the process characteristics and accuracy. Because of the uneven machining and inadequate debris flushing, the technique is less productive and results in high overcut (OC) and hole taper (HT) for the microholes as well as poor material removal rate (MRR). Additionally, the rate of electrode wear affects hole precision. To address these issues, a rotating tool electrode set-up was used to drill microholes in Ti–6Al–4V alloy. The impact of three distinct electrode materials, copper (Cu), tungsten copper (WCu), and tungsten carbide (WC), as well as various process parameters, was investigated. The μEDD was accomplished by changing input process parameters, viz. voltage (V), capacitance (C) and tool rotation speed (TRS) and using Cu, WCu and WC tool electrodes to examine their influence on the process response variables such as MRR, TWR, OC, and HT. The experiments for each electrode were designed using a Taguchi-based L9 array, and the results were examined using Analysis of Variance (ANOVA). Capacitance was found to be the most significant electrical parameter in the μEDD of the titanium alloy. At 10,000 pF capacitance, the WCu electrode showed the highest MRR 0.009247 mm3/min, which was 6.11% and 21.92% higher than the Cu and WC electrodes. In contrast, the WCu electrode had the lowest tool wear rate (TWR) of 0.002033 mm3/min, which was 280.61% and 61.61% less than the Cu and WC electrodes, respectively. The WC electrode exhibited more accuracy by reducing the OC and HT compared to the Cu and WCu electrodes. The Cu tool electrode owing to its lower melting point and high thermal conductivity ensued in higher TWR than the WCu and WC electrodes. The used of rotary tool enabled a steady machining and proper flushing of debris. The impact of the tool materials and process variables on the surface quality of manufactured micro-holes was also explored using scanning electron microscopy (SEM) and energy-dispersive X-ray analysis (EDX). The WCu electrode showed higher carbon deposition on the hole surface than the Cu and WC electrodes.

Multi principal element alloy particle reinforced metal matrix composites: Synthesis, microstructure, and mechanical aspects

The industrial usage of multi principal element alloys (MPEAs) is rare due to manufacturing constraints. This gap was bridged by manufacturing single-step MPEA particles reinforced composite via friction stir processing (FSP) of NiTi and Fe powders with Cu base metal, using WC tool at rotational and traverse speeds of 560 rpm and 16 mm/min, respectively. Ultra-refined Cu matrix, having average grain size of ∼2.7 µm, containing uniformly decorated MPEAs was obtained. Microhardness of composite was 175HV, marking enhancement of 59% from base metal. The application of FSP for formation of MPEA particles having configurational entropy of medium entropy alloys (1R<ΔSmix<1.5R) is novel.

Research on diffusion wear mechanism of WC tool cutting Al2024 based on MD

Al2024 belongs to a typical Al-Cu-Mg series alloy. It has the advantages of high-strength, low-specific gravity, stress resistance, corrosion resistance, good heat resistance, and high fatigue resistance. It is widely used in aerospace, automobiles, ships, chemicals, and other fields. Aluminum alloys play a pivotal role in industry and manufacturing. Cemented carbide tools are often used in the processing of aluminum alloys, and diffusion wear is prone to occur during the processing. It is of great significance to study the diffusion phenomenon of WC tools in the process of cutting aluminum alloys for improving tool life and workpiece surface machining accuracy. In this paper, based on the molecular dynamics (MD) simulation method, the WC tool and the Al2024 model were established, the Morse potential parameters between the tool and the workpiece atoms were calculated, and the diffusion wear mechanism of the WC tool in the process of cutting Al2024 was studied. Through the displacement nephogram in the tool-worker X direction, it is found that the workpiece atoms have a tendency to diffuse to the tool. Using the mean square displacement (MSD) method, the diffusion velocities of Al, Cu, and Mg atoms in the workpiece were obtained. The results show that the activation energy of atomic vacancies at the grain boundary is smaller than that at the lattice, and the Al, Cu, and Mg atoms at the grain boundary of the workpiece are more likely to diffuse, and the diffusion rate of Mg atoms is the fastest. The total energy of single atoms in the cutting process was analyzed, and it was found that the energy required for Al, Cu, and Mg elements at the grain boundary of the workpiece to diffuse into the WC tool and the energy required for the Mg and Al elements at the workpiece lattice to diffuse into the WC tool were satisfied.