The Tool Life and Coating-Substrate Adhesion of AlCrSiN-Coated Carbide Cutting Tools Prepared by LARC with Respect to the Edge Preparation and Surface Finishing

Abstract

Nanocomposite AlCrSiN hard coatings were deposited on the cemented carbide substrates with a negative substrate bias voltage within the range of −80 to −120 V using the cathodic arc evaporation system. The effect of variation in the bias voltage on the coating-substrate adhesion and nanohardness was investigated. It was clear that if bias voltage increased, nanohardness increased in the range from −80 V to −120 V. The coating deposited at the bias voltage of −120 V had the highest nanohardness (37.7 ± 1.5 GPa). The samples were prepared by brushing and wet microblasting to finish a surface and prepare the required cutting edge radii for the tool life cutting tests and the coating adhesion observation. The indents after the static Mercedes indentation test were studied by scanning the electron microscope to evaluate the coating-substrate adhesion. The longer time of edge preparation with surface finishing led to a slight deterioration in the adhesion strength of the coating to the substrate. The tool wear of cemented carbide turning inserts was studied on the turning centre during the tool life cutting test. The tested workpiece material was austenitic stainless steel. The cemented carbide turning inserts with larger cutting edge radius were worn out faster during the machining. Meanwhile, the tool life increased when the cutting edge radius was smaller.

Development of DLC-Coated Solid SiAlON/TiN Ceramic End Mills for Nickel Alloy Machining: Problems and Prospects

“…In addition, the presence of a nitride sublayer under the DLC layer based on the Cr-Al-Si system increases the strength of the external DLC layer's adhesive bond with Nevertheless, due to the introduction of silicon into its composition during the deposition process, a formed DLC-Si layer makes it possible to significantly increase the DLC layer's thermal stability and expand the field of application of such coatings in this case [75,81,82]. In addition, the presence of a nitride sublayer under the DLC layer based on the Cr-Al-Si system increases the strength of the external DLC layer's adhesive bond with the tool base [83][84][85] and contributes to the formation of secondary wear-resistant phases during high-temperature heating [86][87][88][89][90]. When heated in oxygen, the coating components can form nonstoichiometric oxide phases, contributing to the change in the contact interaction between the ceramic article and the counter body nature [91][92][93].…”

Effect of Laser Heating on the Life of Cutting Tools Coated with Single- and Multilayer Coatings Containing a TiN Layer

“…There are two main advantages of using lasers in material processing [ 18 , 23 , 24 , 25 , 26 , 27 , 28 ]. The first advantage relates to the production of laser coatings (often known as plating or cladding in the case of laser-produced coatings) from powders, pastes, thin films, rods, and wires or by depositing sprayed suspensions [ 18 , 26 , 28 , 29 , 30 ]. The use of such coatings is primarily aimed at increasing the abrasive and erosive wear resistance, as well as heat and corrosion resistance, of materials [ 26 , 27 , 30 , 31 , 32 , 33 ].…”

An Investigation of the High-Frequency Ultrasonic Vibration-Assisted Cutting of Steel Optical Moulds

“…Steel is a fascinating die material in the precision mould industry for injection moulding of plastic optical lenses and low-Tg glass. To machine steel materials, coated carbide tools [ 1 , 2 ] and cubic boron nitride (CBN) tools [ 3 ] are widely applied. Diamond tools possess a nanometric edge radius, form reproducibility, and excellent wear resistance, so they are extensively used in ultra-precision machining technology, such as fly cutting and single-point diamond turning (SPDT), and are capable of producing components with submicrometric form accuracy and surface roughness in the nanometre range on plastic and non-ferrous materials such as copper, aluminium, brass, etc.…”