Investigation on Cutting Feasibility on Ni-CBN on HSS Substrates for Aerospace Material

Abstract

The study involves coating the high-speed steel (HSS) tool with cubic Boron via electroless nickel co-deposition. The surface coating of Ni-CBN was deposited via electroless nickel where the process of involved chemical reactions as the ceramic CBN powders was embedded within the layer. By introducing the electroless nickel process, the coating cost and procedure could be simplified. The electroless deposition has been extensively practised in industry, and the most prevalent coating offers excellent corrosion, wear and abrasion resistance, ductility, lubricity, electrical properties, and hardness. Thus, the introduction of the new electroless nickel (Ni-CBN) tools can be a contribution to the industry. This paper discussed on comparing the performance of Nickel-cubic boron nitride (Ni-CBN) HSS tool substrates and with uncoated HSS tool for its surface tolerance in milling of Aluminium Alloy 7075. The process variables selected during experimentation based on Taguchi L9 are cutting speed, feed rate, and depth of cut with three different levels for each parameter. Result shows, the lowest flank wear for coated measured is 51.34 μm while the highest is 380.26 μm. The highest surface roughness for uncoated is 1.154 μm and lowest 0.42μm. Meanwhile, for coated substrates, the highest Ra is 0.787μm and lowest 0.251μm. At the end of the analysis, the Ni-CBN HSS cutting tools are generally able to slightly reduce the tool wear with the longest tool lifetime 195 minutes compared uncoated 143 minutes. Therefore, it is concluded that the Ni-CBN HSS tool end mill are generally able to reduce the tool wear.

Characterisation and Application of Nickel Cubic Boron Nitride Coating via Electroless Nickel Co-Deposition

“…High-value of feed rate, spindle speed and depth of cut and cutting time will cause significant tool wear. The previous studies found that the cutting speed and feed rate interaction is significantly affecting the tool wear [52,55,56].…”

“…This demonstrates spindle speed as the significant factor that affects surface roughness. Spindle speed is the most critical machining parameter affecting surface roughness because it is substantially influenced [56]. The table also represents the Taguchi response to determine the optimal factors affecting surface roughness.…”

“…The slope between the horizontal line and spindle speed is more pronounced than the depth of cut and feed. The changes in spindle speed significantly affect the surface roughness [56]. The optimum machining settings are determined at spindle speed value of 1860 RPM, feed rate of 334 mm/min, and depth of cut of 2 mm.…”

YSZ/Ni double‐shell powder via surface electroless deposition tuned by an active kinetic model

“…3,4 High melting point metal nickel is a nice choice due to its excellent properties. 5,6 Electroless nickel (EN) deposition is an effective and important surface modification technology, which not only maintains the characteristics of the material itself but also endows new characteristics such as electromagnetics, [7][8][9][10][11] heat, [12][13][14] and optics. 15,16 Various metal patterns have been effectively, uniformly, and controllably grown on a matrix of various shapes and materials in the absence of an electron source, ultrahigh vacuum, high pressure, or high temperature.…”

“…Due to the inherent brittleness and hardness of ceramic materials, YSZ materials are often mixed with others to form ceramic‐matrix materials 3,4 . High melting point metal nickel is a nice choice due to its excellent properties 5,6 . Electroless nickel (EN) deposition is an effective and important surface modification technology, which not only maintains the characteristics of the material itself but also endows new characteristics such as electromagnetics, 7–11 heat, 12–14 and optics 15,16 .…”