Wear Performance of Multilayer-Coated Carbide Tools

Abstract

Three multilayer-coated carbides [two trigon-shaped inserts: Ti(C,N)/TiC/ Al 2 O 3 (T1), Ti(C,N)/ Al 2 O 3 /TiN (T2) and one 80°-rhomboid shaped insert: TiC/Al 2 O 3 /TiN (T3)] were used to machine a martensitic stainless steel at various combinations of cutting speed and feed rate without coolant to assess their wear performance. Significant nose wear and chipping/fracture of the cutting edge were the predominant failure modes affecting tool performance at higher speed conditions. Plucking of tool materials was the main rake face wear phenomenon observed on T1 grade insert with alumina as the top-layer coating when machining at the lower speed conditions. Attrition and plastic flow were the main wear mechanisms observed on the ceramic coating layers, with dissolution-diffusion being the probable wear mechanism of the tool grades where tungsten carbide substrate had direct contact with the flowing chip. The fitted statistical wear models revealed T3 grade insert with 80°rhomboid shape as having the highest speed-feed capability, resulting in the highest material removal rate relative to T1 and T2 grade inserts with trigon shapes.

An experimental study of tool wear and cutting force variation in the end milling of Inconel 718 with coated carbide inserts

“…Byrne and Bienia [7] found that TiN coated HSS was suitable for the machining of high nickel content soft magnetic materials from a tool life point of view although a large scatter in tool life occurred. Ezugwu et al [8] investigated the performance of multiplayer-coated carbide tools in the turning of a martensitic stainless steel without coolant, and found that the predominant failure modes at higher speed conditions were significant nose wear and chipping/fracture of the cutting edge. In recent years, M. Alauddin et al [9] studied the influence of the machining conditions on the average cutting forces in the end milling of Inconel 718 under dry conditions using uncoated carbide inserts, but the problems of tool wear were not addressed.…”

Avaliação da usinabilidade do aço inoxidável supermartensítico na operação de torneamento

“…Observa-se que o inserto MC 7015 apresentou o menor valor médio do desgaste de flanco, seguido de perto pelo inserto MC 7025 e pelo MP 7035. Uma possível explicação do comportamento quanto ao desgaste de flanco (VBc) dos insertos está relacionada à perda dos revestimentos em função dos mecanismos de desgaste predominantes e das tensões na região de corte [21]. O inserto MP 7035 possui revestimento monocamada de (Ti, Al)N com alto teor de Al, o que pode ter contribuído para o desgaste acelerado, enquanto que os insertos MC 7015 e 7025 têm o mesmo revestimento TiC,N + Al 2 O 3 + TiN, porém, são multicamadas que retardam a perda de material.…”

Assessment of cutting forces in high-speed milling of Inconel 718 considering the dynamic effects

“…This transition was believed to be caused by both thermal softening and material damage. Ezugwu et al 8 studied the performance of multiplayer-coated carbide tools in the turning of a martensitic stainless steel without coolant and found that the predominant tool failure modes at higher speed conditions were significant nose wear and chipping/fracture of the cutting edge. Liao et al 9 concluded that cutting temperature, which is believed to be related to the cutting speed, plays a very important role in cutting of Inconel 718.…”