The effect of the built-up-edge(BUE) on the wear of cutting tools

Ramaswami, R.

doi:10.1016/0043-1648(71)90059-7

Cited by 32 publications

(8 citation statements)

References 1 publication

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“…For DLC a, the wear curve follows the TiB 2 curve, with a small decrease in tool wear in the steady state. However, while coatings on samples DLC b, d and e significantly decreased the wear during the running-in stage, only DLC b also limited the machining length needed to achieve steady-state, thereby improving the surface finish of the machined parts [33]. Nevertheless, the width of the stable wear is overall shorter than it is for the TiB 2 -coated tool.…”

Section: Machining Studiesmentioning

confidence: 96%

DLC and DLC-WS2 Coatings for Machining of Aluminium Alloys

et al. 2019

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Machine-tool life is one limiting factor affecting productivity. The requirement for wear-resistant materials for cutting tools to increase their longevity is therefore critical. Titanium diboride (TiB2) coated cutting tools have been successfully employed for machining of AlSi alloys widely used in the automotive industry. This paper presents a methodological approach to improving the self-lubricating properties within the cutting zone of a tungsten carbide milling insert precoated with TiB2, thereby increasing the operational life of the tool. A unique hybrid Physical Vapor Deposition (PVD) system was used in this study, allowing diamond-like carbon (DLC) to be deposited by filtered cathodic vacuum arc (FCVA) while PVD magnetron sputtering was employed to deposit WS2. A series of ~100-nm monolayer DLC coatings were prepared at a negative bias voltage ranging between −50 and −200 V, along with multilayered DLC-WS2 coatings (total thickness ~500 nm) with varying number of layers (two to 24 in total). The wear rate of the coated milling inserts was investigated by measuring the flank wear during face milling of an Al-10Si. It was ascertained that employing monolayer DLC coating reduced the coated tool wear rate by ~85% compared to a TiB2 benchmark. Combining DLC with WS2 as a multilayered coating further improved tool life. The best tribological properties were found for a two-layer DLC-WS2 coating which decreased wear rate by ~75% compared to TiB2, with a measured coefficient of friction of 0.05.

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Section: Machining Studiesmentioning

confidence: 96%

DLC and DLC-WS2 Coatings for Machining of Aluminium Alloys

et al. 2019

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“…It suggests that the composition of sample b is the optimum to prevent Al sticking to the tool rake face as it keeps the best balance between low CoF of the MoS2 and oxidation protection of provided by Ti which could act as barriers for oxygen diffusion [38]. As there is no material adhered to the sample b the surface finish of the machined part as well as tool lifetime would be improved comparing with other samples where BUE is present [13,14]. The worst performance was indicated by samples d and e both having almost the same composition-around 96 at.…”

Section: Edx Element Mappingmentioning

confidence: 99%

“…The higher temperatures during machining facilitates aluminium adhesion to the cutting tool forming a built-up edge (BUE) [12]. When the machined material adheres to the cutting edge of the tool, it changes the geometry of the cutting edge which increases the cutting forces at the tool interface [13]. The size of the BUE increases until some critical size after which it becomes unstable, with the resulting fractured particles being carried into both the chip and new workpiece surface [14].…”

Section: Introductionmentioning

confidence: 99%

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Hybrid Ti-MoS2 Coatings for Dry Machining of Aluminium Alloys

et al. 2017

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Combinatorial deposition, comprising filtered cathodic vacuum arc (FCVA) and physical vapor deposition (PVD) magnetron sputtering is employed to deposit molybdenum disulphide (MoS 2 ) and titanium (Ti) thin films onto TiB 2 -coated tool inserts specifically designed for the dry machining of aluminium alloys. Titanium is deposited by FCVA while MoS 2 is magnetron sputtered. The deposition set up allows several compositions of Ti-MoS 2 to be deposited simultaneously, with Ti content ranging between 5 and 96 at. %, and their machining performances to be evaluated. Milling took place using a CNC Vertical Machining Center at a 877 mm/min feed rate. The effect of different coating compositional ratios on the degree of aluminium sticking when a milling insert is used to face mill an Al alloy (SAE 6061) was investigated using a combination of energy-dispersive X-ray spectroscopy (EDX) and X-ray photoelectron spectroscopy (XPS) analysis. XPS studies suggest that the greater degree of Al sticking on the rake face of the inserts is due to the formation of greater amounts of non-protective Ti-O phases. EDX mapping of the milling inserts after machining reveal that a Ti:MoS 2 ratio of around 0.39 prevents Al from sticking to the tool edges. Since we prevent Al from sticking to the tool surface, the resultant machined surface finish is improved thus validating the machining performance of TiB 2 -coated tools using optimum compositions of Ti:MoS 2 thin film coatings.

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“…This is believed to be the main reason to protect the cutting tool from chipping and flank wear. The friction condition at the tool-material interface is affected by the built-up edge that acts as a protecting layer preventing the cutting edge being in contact with workpiece during machining process [19].…”

Section: Introductionmentioning

confidence: 99%

An experimental study on tool wear behaviour in micro milling of nano Mg/Ti metal matrix composites

Teng

Huo

Shyha

et al. 2018

Int J Adv Manuf Technol

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With the development of MMCs, the mechanical properties of MMCs with small volume fraction of nanosized particles were found to be even superior to that with larger content of micron-sized particles. However, the improved mechanical properties of MMCs bring tremendous challenges such as premature tool failure Tiin machining process. This study exhibits an investigation on tool wear in micro milling of magnesium based MMCs reinforced with 1.98 Vol.% of nano-sized titanium particles using 0.5mm diameter two-flute tungsten carbide micro endmills. The tool wear was characterised both quantitatively and qualitatively by observing tool wear patterns and analysing the effect of cutting parameters on flank wear, reduction in tool diameter, cutting forces, surface roughness, and burr formation. A finite element model was established to understand matrix deformation and interaction between tool-particle and further explain the tool wear phenomena observed. Additionally, cutting performance using AlTiN coated and uncoated was also investigated. The results indicated that the main wear mechanisms were identified as flank wear and edge chipping due to abrasive wear and chip adhesion in uncoated micro endmills. These wear mechanisms were confirmed by chip formation process produced by finite element modelling (FEM). It was also observed that the largest tool wear was occurred at smallest feed per tooth (0.75µm/tooth) and smallest wear was 2 occurred at largest feed per tooth (3µm/tooth). Also, the effect of BUE on tool wear and surface generation was studied.

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The effect of the built-up-edge(BUE) on the wear of cutting tools

Cited by 32 publications

References 1 publication

DLC and DLC-WS2 Coatings for Machining of Aluminium Alloys

DLC and DLC-WS2 Coatings for Machining of Aluminium Alloys

Hybrid Ti-MoS2 Coatings for Dry Machining of Aluminium Alloys

An experimental study on tool wear behaviour in micro milling of nano Mg/Ti metal matrix composites

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