Comparative performance analysis of cemented carbide, TiN, TiAlN, and PCD coated inserts in dry machining of Al 2024 alloy

Uddin, Ghulam Moeen; Joyia, Farooq Mustafa; Ghufran, Muhammad; Khan, Sarmad Ali; Raza, Mohsin Ali; Faisal, M. K.; Arafat, Syed Muhammad; Zubair, Syed Wasim Hassan; Jawad, Muhammad; Zafar, Muhammad Qasim; Irfan, Muhammad; Waseem, Bilal; Chaudhry, I.; Zeid, Ibrahim

doi:10.1007/s00170-020-06315-5

Cited by 31 publications

(10 citation statements)

References 66 publications

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“…The lower lubricating effect of an emulsion causes high thermal load on the guide pads, which is particularly challenging with ta-C coating. Uddin et al established that TiN coatings provide decreased tool wear, while simultaneously lowering surface quality in machining of adhesive aluminium alloys [39]. In general, drilling AISI 304 causes stronger wear on the guide pads using emulsion compared to drilling with oil.…”

Section: Discussionmentioning

confidence: 99%

Investigation into deep hole drilling of austenitic steel with advanced tool solutions

Felinks

Rinschede

Biermann

et al. 2021

Int J Adv Manuf Technol

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Deep hole drilling processes for high-alloyed materials are characterised by worn guide pads and chatter vibrations. In order to increase feed rates, process stability and bore quality in STS deep hole drilling, various investigations were carried out with adjustments to the tool. First, a new process chain for the production of tribologically optimised guide pads and their effects on the guide pad shape is described in detail. The results of these studies show that the shape change in the area of the axial run-in chamfer through a micro finishing process leads to a better bore hole quality. Furthermore, the influence of guide pad coating and cooling lubricant on the deep hole drilling process was investigated. In addition, the machining of the austenitic steel AISI 304 is analysed by using a conventional steel boring bar and an innovative carbon fibre reinforced plastic (CFRP)-boring bar. While the conventional drill tube oscillates with different eigenfrequencies, the CFRP-boring bar damps chatter vibrations of the drill head and stabilises the process. Even at higher feed rates up to f = 0.3 mm, it is possible to machine austenitic, difficult-to-cut-materials with significantly reduced vibrations.

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Section: Discussionmentioning

confidence: 99%

Investigation into deep hole drilling of austenitic steel with advanced tool solutions

Felinks

Rinschede

Biermann

et al. 2021

Int J Adv Manuf Technol

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“…30 Dry machining of AMCs generates undesirable BUE on the cutting tool surface. 31–33 Therefore, polycrystalline diamond (PCD) tools appear a better choice, but these are highly expensive. 34–36 The MTJNL 1616 H16 WIDAX with ISO specifications of tool holder and TNMG 160408 tungsten carbide inserts (triangular shape, D 9.53 mm, L 16.50 mm, Rε 0.8 mm, Figure 4) have been used for the turning operation in this study due to low cost and better tool life.…”

Section: Methodsmentioning

confidence: 99%

Characterization and optimization analysis on surface finish and energy consumption in turning of Al-4032/GMP MMC produced by stir casting

Saini

Singh

2022

Proceedings of the Institution of Mechanical Engineers, Part C:

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Control of energy expenditure in computer numerical control (CNC) machining is needed for eco-friendly operation of machining operations. Production industries deeply emphasize the improvement of productivity and saving in cost. The aluminum-based metal matrix composites (AMCs) can be substituted for metals for their mechanical properties in several applications. However, to bring in composite to usage, generally demand certain machining operation, which is quite challenging. This paper presents fabrication, characterization, and machining (turning) of Al-4032/6%GMP (granite marble powder) composite. Optical micrographs (OM) and scanning electron microscopy (SEM) with energy dispersive x-ray analysis (EDAX) have been used for the portrayal of the composite microstructure, surface topography, and fracture behavior. Also, mechanical characterization (tensile strength, micro-hardness, and impact strength) of the fabricated AMC has been carried out. The AMC samples have been examined for machinability for CNC turning operation. Cutting speed, feed rate, and depth of cut are the cutting parameters selected for the machining experiments. The response surface methodology (RSM)-based desirability function has been used to obtain the best combination of parameters for achieving the desired objectives. Experimental results demonstrate the built-up edge (BUE) formation on cutting insert and interfacial bonding of particles on workpiece surface at low cutting speed. Generally, smooth cutting operation has been observed at cutting speeds above 100 m/min. Best surface finish (1.38 μm) and minimum energy consumption (0.27 kWh) have been observed at cutting speed 176 m/min, feed rate 0.15 mm/rev, and depth of cut 0.45 mm.

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“…The results show that the cutting force and cutting temperature of AlTiN-coated tools are smaller than those of uncoated tools. Although the coating can improve the hardness and wear resistance of the substrate to a certain extent, some scholars have found that the adsorption of a single coating and the substrate is poor, which affects its mechanical properties (Uddin et al , 2021; Kremer et al , 2008).…”

Section: Introductionmentioning

confidence: 99%

Study on surface properties of coated WC-Co alloy based on laser reduction process

Yang,

Wang,

Xiao

2024

ILT

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Purpose The purpose is to explore the improvement mechanism of coating and laser micro-texture on the surface properties of cemented carbide, so as to give full play to the technical advantages of both and improve the overall surface properties of the material. Design/methodology/approach The surface hardness of the coating was measured by a microhardness tester, the surface element composition of the coating was tested by an energy spectrum analyzer and the phase was measured by an X-ray diffractometer to observe the surface morphology after the friction and wear experiment. Findings Laser will generate new oxide and nitride films on the surface of the coating, which will improve the hardness of the coating surface and the bonding strength between the coating and the substrate. The surface micro-texture can collect wear debris during the friction process, reduce abrasive wear and play a good role in inhibiting the expansion of the coating failure zone. Originality/value Most of the research on traditional laser coating is to process micro-texture first and then coating. This study is the opposite. In this paper, the modification effect of laser on the coating surface is explored, and the parameters of laser and coating are optimized, which paves the way for the subsequent milling experiments of textured coating tools.

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Comparative performance analysis of cemented carbide, TiN, TiAlN, and PCD coated inserts in dry machining of Al 2024 alloy

Cited by 31 publications

References 66 publications

Investigation into deep hole drilling of austenitic steel with advanced tool solutions

Investigation into deep hole drilling of austenitic steel with advanced tool solutions

Characterization and optimization analysis on surface finish and energy consumption in turning of Al-4032/GMP MMC produced by stir casting

Study on surface properties of coated WC-Co alloy based on laser reduction process

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