Investigation of Coated Cutting Tool Performance during Machining of Super Duplex Stainless Steels through 3D Wear Evaluations

Ahmed, Yassmin Seid; Paiva, José Mario; Covelli, Danielle; Veldhuis, Stephen C.

doi:10.3390/coatings7080127

Cited by 33 publications

(20 citation statements)

References 26 publications

(30 reference statements)

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“…The removed portions of BUE adhere partly to the chip undersurface and partly to the machined surface. This causes the chip undersurface be rough, and friction at the chip–tool interface increases, leading to a reduction the chip speeds during the chip flow and an increase in the area of contact between tool and chip on the rake face surface [ 34 ].…”

Section: Resultsmentioning

confidence: 99%

Effect of Built-Up Edge Formation during Stable State of Wear in AISI 304 Stainless Steel on Machining Performance and Surface Integrity of the Machined Part

et al. 2017

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During machining of stainless steels at low cutting -speeds, workpiece material tends to adhere to the cutting tool at the tool–chip interface, forming built-up edge (BUE). BUE has a great importance in machining processes; it can significantly modify the phenomenon in the cutting zone, directly affecting the workpiece surface integrity, cutting tool forces, and chip formation. The American Iron and Steel Institute (AISI) 304 stainless steel has a high tendency to form an unstable BUE, leading to deterioration of the surface quality. Therefore, it is necessary to understand the nature of the surface integrity induced during machining operations. Although many reports have been published on the effect of tool wear during machining of AISI 304 stainless steel on surface integrity, studies on the influence of the BUE phenomenon in the stable state of wear have not been investigated so far. The main goal of the present work is to investigate the close link between the BUE formation, surface integrity and cutting forces in the stable sate of wear for uncoated cutting tool during the cutting tests of AISI 304 stainless steel. The cutting parameters were chosen to induce BUE formation during machining. X-ray diffraction (XRD) method was used for measuring superficial residual stresses of the machined surface through the stable state of wear in the cutting and feed directions. In addition, surface roughness of the machined surface was investigated using the Alicona microscope and Scanning Electron Microscopy (SEM) was used to reveal the surface distortions created during the cutting process, combined with chip undersurface analyses. The investigated BUE formation during the stable state of wear showed that the BUE can cause a significant improvement in the surface integrity and cutting forces. Moreover, it can be used to compensate for tool wear through changing the tool geometry, leading to the protection of the cutting tool from wear.

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Section: Resultsmentioning

confidence: 99%

Effect of Built-Up Edge Formation during Stable State of Wear in AISI 304 Stainless Steel on Machining Performance and Surface Integrity of the Machined Part

et al. 2017

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“…Al-rich PVD nitride coatings have been developed with dense nanocrystalline or columnar microstructures, high oxidation resistance, very good elevated temperature mechanical properties, low thermal conductivity at elevated temperature and potential for tribological adaptability through formation of complex tribo-films . Consequently, they have shown excellent performance in machining aerospace alloys such as Ni-based superalloys (Inconel 718, Waspaloy, ME16) [10,13,18], titanium alloys [7,9,18], and other hard-to-cut materials such as hardened steel [4,14,15,17], stainless steel [8] and super duplex stainless steel [30].…”

Section: Introductionmentioning

confidence: 99%

Micro-impact testing of AlTiN and TiAlCrN coatings

Beake

Isern

Endrino

et al. 2019

Wear

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A novel micro-scale repetitive impact test has been developed to assess the fracture resistance of hard coatings under dynamic high strain rate loading. It is capable of significantly higher impact energies than in the nano-impact test. It retains the intrinsic depth-sensing capability of the nano-impact test enabling the progression of the damage process to be monitored throughout the test, combined with the opportunity to use indenters of less sharp geometry and still cause rapid coating failure. The micro-impact test has been used to study the resistance to impact fatigue of Al-rich PVD nitride coatings on cemented carbide. The impact fatigue mechanism has been investigated in nano-and micro-scale impact tests. Coating response was highly load-dependent. A Ti 0.25 Al 0.65 Cr 0.1 N coating with high H 3 /E 2 performed best in the nano-and micro-impact tests although it was not the hardest coating studied. The

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“…Increasing tool-chip contact length reduces the shear plane angle and this leads to increased shear stress [14]. In addition, high spindle speed associated with high cutting temperature, leads to workpiece softening and then reduces the cutting forces [2].…”

Section: Evaluation Of the Experimental Resultsmentioning

confidence: 99%

“…Duplex stainless steels are a specific type of stainless steel that have a biphasic microstructure consisting of approximately 50% ferrite and 50% austenite in volume. Due to their microstructure, duplex stainless steels present a good combination of ferritic and austenitic steel properties, including increased toughness, high mechanical strength, and high corrosion resistance in several environments [2]. However, the tools employed to machine them have a shorter life than those used in the machining of austenitic alloys due to the high work hardening rate and ductility of duplex stainless-steel alloys.…”

Section: Introductionmentioning

confidence: 99%

“…However, the machining of these steels is very difficult due to their higher ductility, strength, work hardening rate and low thermal conductivity [2], resulting in short tool life, limited metal removal rate, high cutting forces, and power consumption. Stainless steels are divided into five families: austenitic, ferrite, martensitic, duplex, and precipitation hardening alloys [3].…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Prediction and Optimization of Drilling Parameters in Drilling of AISI 304 and AISI 2205 Steels with PVD Monolayer and Multilayer Coated Drills

Youssef

El-Hofy

Ahmed

2018

JMMP

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Due to their high ductility, high durability, and excellent corrosion resistance, stainless steels are attractive materials for a variety of applications. However, high work hardening, low thermal conductivity, and high built-up edge (BUE) formation make these materials difficult to machine. Rapid tool wear and high cutting forces are the common problems encountered while machining these materials. In the present work, the application of Taguchi optimization methodology has been used to optimize the cutting parameters of the drilling process for machining two stainless steels: austenitic AISI 304 and duplex AISI 2205 under dry conditions. The machining parameters which were chosen to be evaluated in this study are the tool material, cutting speed, and feed rate, while, the response factors to be measured are the tool life (T), cutting force (F c ), and specific cutting energy (k s ). Additionally, empirical models were created for predicting the T, F c and k s using linear regression analysis. The results of this study show that AISI 2205 stainless steel has a shorter tool life, a higher cutting force, and a higher specific cutting energy than AISI 304 stainless steel. In addition, the Taguchi method determined that A 3 B 1 C 1 and A 3 B 3 C 1 (A 3 = TiN-coated twist drill, B 1 = 13 m/min, B 3 = 34 m/min, C 1 = 0.12 mm/rev) are the optimized combination of levels for the best tool life and the lowest cutting force, respectively. Meanwhile, the optimized combination of levels for all three control factors from the analysis, which provides the lowest specific cutting energy, was found to be A 3 B 1 C 3 (A 3 = TiN-coated twist drill, B 1 = 13 m/min, C 3 = 0.32 mm/rev) for both stainless steels.

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Investigation of Coated Cutting Tool Performance during Machining of Super Duplex Stainless Steels through 3D Wear Evaluations

Cited by 33 publications

References 26 publications

Effect of Built-Up Edge Formation during Stable State of Wear in AISI 304 Stainless Steel on Machining Performance and Surface Integrity of the Machined Part

Effect of Built-Up Edge Formation during Stable State of Wear in AISI 304 Stainless Steel on Machining Performance and Surface Integrity of the Machined Part

Micro-impact testing of AlTiN and TiAlCrN coatings

Prediction and Optimization of Drilling Parameters in Drilling of AISI 304 and AISI 2205 Steels with PVD Monolayer and Multilayer Coated Drills

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