Application of Adaptive Materials and Coatings to Increase Cutting Tool Performance: Efficiency in the Case of Composite Powder High Speed Steel

Abstract

The paper proposes a classification of adaptive materials and coatings for tool purposes, showing the ability to adapt to external heat and power influences, thereby improving tool life. Creating a cutting tool made of composite powder high speed steels containing refractory TiC, TiCN, and Al2O3 compounds for milling 41CrS4 steel demonstrated the effectiveness of the adaptive materials. The tool material characteristics under the external loads’ influence and the surface layer adaptation to the heat–power exposure conditions were shown by the temperature field study using a semiartificial microthermocouple method (the level of fields is reduced by 20%–25% for 80% HSS + 20% TiCN), frictional interaction high-temperature tribometry (the coefficient of friction did not exceed 0.45 for 80% HSS + 20% TiCN at +20 and 600 °C), laboratory performance tests, and spectrometry of the surface layer secondary structures. Spectral analysis shows the highest spectrum intensity of TiC2 after 5 min of running in. After 20 min of milling (V = 82 m/min, f = 0.15 mm/tooth), dicarbide decomposes and transits to thermally stable secondary phase films of good lubricity such as TiO (maximum) and TiN (partially). There was an increase in tool life of up to 2 times (>35 min for 80% HSS + 20% TiCN), and a decrease in the roughness of up to 2.9 times (Ra less than 4.5 µm after 25 min of milling).

Experimental investigation on the performance of ceramics and CBN cutting materials during dry machining of cast iron: Modeling and optimization study using RSM, ANN, and GA

“…This difference between different cutting inserts is attributed to the physio-mechanical characteristics of each cutting material 32 and the coating layer (TiN/PVD) which acts as a barrier to improve the chemical and thermal inertia as well as the wear resistance on the flank and leading surfaces of the tool. 33 Figure 5 (a, b) expresses the wear morphology ( Vb ) of the four cutting inserts tested for two cutting speeds of (450 and 650) m/min while keeping f = 0.08 mm/rev and ap = 0.25 mm constant. The analysis of the results clearly shows that the wear ( Vb ) is sensitive to the variation of ( Vc ) and the nature of the cutting material.…”

Tribological properties of high-entropy high-speed steels under conditions of friction on stainless steel 12H18N9T

“…Currently, the performance characteristics of tools made of high-speed steels (HSS) are increased by chemical-thermal treatment, deposition of coatings, laser hardening methods and other methods related to the modification of the surface or volume properties of the material, as well as through the development of new grades of HSS [1][2][3][4][5]. The ability to predict a priori some operational characteristics of experimental compositions of tool cutting materials (TCM) is provided by the study of thermodynamic aspects of processes of wear during friction (cutting).…”