Tribological and Wear Performance of Carbide Tools with TiB2 PVD Coating under Varying Machining Conditions of TiAl6V4 Aerospace Alloy

Abstract

Tribological phenomena and tool wear mechanisms during machining of hard-to-cut TiAl6V4 aerospace alloy have been investigated in detail. Since cutting tool wear is directly affected by tribological phenomena occurring between the surfaces of the workpiece and the cutting tool, the performance of the cutting tool is strongly associated with the conditions of the machining process. The present work shows the effect of different machining conditions on the tribological and wear performance of TiB 2 -coated cutting tools compared to uncoated carbide tools. FEM modeling of the temperature profile on the friction surface was performed for wet machining conditions under varying cutting parameters. Comprehensive characterization of the TiB 2 coated vs. uncoated cutting tool wear performance was made using optical 3D imaging, SEM/EDX and XPS methods respectively. The results obtained were linked to the FEM modeling. The studies carried out show that during machining of the TiAl6V4 alloy, the efficiency of the TiB 2 coating application for carbide cutting tools strongly depends on cutting conditions. The TiB 2 coating is very efficient under roughing at low speeds (with strong buildup edge formation). In contrast, it shows similar wear performance to the uncoated tool under finishing operations at higher cutting speeds when cratering wear predominates.

Electrochemical Water Oxidation in Acidic Solution Using Titanium Diboride (TiB2) Catalyst

“…X‐ray photoelectron spectroscopy (XPS) measurements were performed at various time intervals on TiB 2 electrodes operated at j =10 mA cm −2 . The high‐resolution XP spectrum of the B 1s region (Figure ) prior to OER shows peaks at 187.6 and 192.9 eV, corresponding to TiB 2 and B 2 O 3 respectively . With increasing reaction times the peak intensity at 189.5 eV increases, which can be assigned to growing amounts of TiBO x .…”

Numerical Simulation Applied to PVD Reactors: An Overview

“…Some software and platforms have support services to assist users in solving problems that arise in projects. PVD coatings mechanical properties prediction ANSYS 12.0 [7] Creation of a three-dimensional model describing flow fields and chemical reactions in Claus reactors COMSOL Multiphysics [24] Tribological performance and wear of coated cutting tools AdvantEdg 7.1 [16] Development of the model to evaluate the thermal performance of a solar tubular reactor ANSYS-CFX 14.0 [25] Computer simulation of internal stresses on the PVD coatings ANSYS [17] CFD analysis of Pd-Ag membrane reactor performance during process COMSOL Multiphysics 5.2.1 [29] Coating fracture surface study ABAQUS [77] Fluid dynamics and reaction assessment of diesel oil hydro treating reactors ANSYS-CFX 14.0 [30] Film thickness effect on mechanical properties of PVD coated tools DEFORM and ANSYS [78] Neutral gas flow simulations in an industrial PVD reactor ANSYS FLUENT 14.0 [31] Defects and material deformation study LS-DYNA [79] Prediction of velocity profiles, pressure profiles, density profiles and process gas distribution across the sputtering chamber ANSYS FLUENT [35] Estimate the thermo-mechanical properties of plasma sprayed composite coatings ANSYS-APDL (Parametric Design Language) [83] Modeling on chemical looping combustion (CLC) reactor with a finite volume based CFD method Not defined [94] After analyzing the literature it is observed that FEM is generally used to study, optimize or solve problems associated with mechanical properties, namely, adhesion, wear, stresses in the coating, the influence of the coating thickness, among others. Regarding CFD, there are studies associated with solving problems in aerodynamics, fluid flow, temperature, mass transport, heat transfer, among others.…”

“…Due to the strong importance of these characteristics, many studies have been done in the field of mathematical modeling and numerical simulation of coatings. One of the most influent characteristics in the performance of the coatings' mechanical properties is the thermal conductivity of the substrates and, for this reason, has been also deeply studied in the last decade [16]. In these works, the correct data treatment is important as well as the thermal and mechanical analysis and the interpretation of the simulation results [17].…”

“…Paiva et al [16] studied the wear and tribological performance of TiB 2 coatings used on cutting tools under different machining conditions. The FEM simulation was done to model the problem and thus study the friction surface.…”

Effect of the Adaptive Response on the Wear Behavior of PVD and CVD Coated Cutting Tools during Machining with Built Up Edge Formation

“…Moreover, during the machining of Ti, a dynamically formed thermal barrier TiC interlayer is formed at the built-up–carbide tool interface [ 28 ]. However, the predominant wear mechanism of the cutting tool is significantly altered as the cutting speed increases [ 40 ]. The intensity of built-up edge formation is lower at higher speeds (built-up is intensively worn out) [ 40 ].…”