Cyclic heat-up and damage-relevant substrate plastification of single- and bilayer coated milling inserts evaluated numerically

Nemetz, Andreas W.; Daves, Werner; Klünsner, Thomas; Ecker, Werner; Schäfer, Jonathan; Czettl, Christoph; Antretter, Thomas

doi:10.1016/j.surfcoat.2019.01.008

Cited by 27 publications

(3 citation statements)

References 33 publications

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“…It is apparent that all ℎ , dependencies show similar qualitative behaviour, i.e. an increase in compressive stress and subsequent formation of radial tensile stresses, as discussed in our previous reports [3][4][5][6][7][8][9][10][11][12][13][14][15][16][17][18][19][20]. In the data, one can identify (i) varying maximum magnitudes of individual ℎ , dependencies (occurring in both domains, tensile and compressive alike) as well as (ii) slightly different shapes of the dependencies ℎ , ( ).…”

Section: Iiib Single Laser Pulse Experimentssupporting

confidence: 82%

“…The cyclic thermo-mechanical fatigue of WC-Co composites has been studied both experimentally [6,7,8] as well as using simulation tools to quantify thermal metal machining tool loads [9,10]. In order to predict the degree of local damage induced by the interrupted tool-workpiece contact and wear, a variety of material parameters have to be taken into account, such as CTEs, thermal conductivities and elasto-plastic properties of the coating-substrate composite, all of which are dependent on temperature, crystallite size as well as geometry and the time-scale of the underlying process.…”

Section: Introductionmentioning

confidence: 99%

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20 Hz synchrotron X-ray diffraction analysis in laser-pulsed WC-Co hard metal reveals oscillatory stresses and reversible composite plastification

Gruber

Kiefer

Rössler

et al. 2019

International Journal of Refractory Metals and Hard Materials

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The lifetime of WC-Co inserts used in cutting processes, such as milling, is limited by millisecond temperature and mechanical pulses, which occur as a result of interrupted tool-workpiece contact, thermal fatigue and wear. In the current work, synchrotron X-ray diffraction (XRD) was used in conjunction with a pulsed laser heating setup to characterise the time-dependent development of stresses and microstructure in locally irradiated WC-Co inserts coated by chemical vapour deposition with 6.5 and 3.5 µm thick TiCN and α-Al2O3 films, respectively. Diffraction data from the WC-Co phase were used to evaluate the time and temperature-dependent evolution of in-plane stresses, thermal strains and integral breadths of WC diffraction peaks in experiments with a single and five successive laser shocks applied within 2.2 and 20 seconds, respectively, using a laser spot diameter of ~5.8 mm and an X-ray beam size of 1 × 1 mm 2. The laser heating induces the formation of compressive stresses in the inserts' substrates. Above a temperature of ~750°C, at the onset of WC-Co composite plastification, compressive stresses relax and then vanish in WC at the maximal applied temperature of ~1300°C, followed by the build-up of tensile stresses. The applied cyclic heating up and cooling down led to the repetitive formation of compressive and tensile stresses, with temperature dependencies oscillating with the number of applied laser pulses. The observed relatively high tensile stress level of ~1100 MPa in WC was a consequence of the stabilising function of the coating, which hindered the initiation of surface hot cracks and stress relaxation. The stress evolution was coupled with changes in XRD peak broadening, which however strongly depended on the particular hkl reflections and showed oscillatory behaviour within a single temperature cycle. In summary, the unique diffraction setup revealed stress levels and provides insight into the WC-Co composite plastification mechanism governing the stress build-up and relaxation in locally thermo-shocked WC-Co inserts at millisecond time resolution.

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Section: Iiib Single Laser Pulse Experimentssupporting

confidence: 82%

Section: Introductionmentioning

confidence: 99%

20 Hz synchrotron X-ray diffraction analysis in laser-pulsed WC-Co hard metal reveals oscillatory stresses and reversible composite plastification

Gruber

Kiefer

Rössler

et al. 2019

International Journal of Refractory Metals and Hard Materials

Self Cite

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“…The chip formation involves the plastic deformation at shear zones, generating contact stress and heat in cutting tools, which are subjected to abrasive and adhesive wear. When using workpiece materials with relatively high thermal conductivities, the generated heat is transported away with chip flow over the tool rake face [2][3][4][5]. In the case of continuous cylindrical turning, the workpiece rotates around its center axis, while a sharp-edged tool is set to a certain depth of cut for performing a facing operation towards the workpiece rotational center [6].…”

Section: Introductionmentioning

confidence: 99%

Characteristics and Cutting Performance of CVD Al2O3 Multilayer Coatings Deposited on Tungsten Carbide Cutting Inserts in Turning of 24CrMoV5-1 Steel

Zhu,

Achache,

Motta

et al. 2023

Coatings

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In this work, TiN/Ti(C,N)/Al2O3 multilayer coatings were deposited using an industrial-scale thermal CVD system. Two polymorphs of Al2O3, the stable α- and the metastable κ-Al2O3, were obtained by the deposition of specific bonding layers at the Al2O3/Ti(C,N) interface. The comparable hardness and elastic moduli of α- and κ-Al2O3 multilayer coatings were measured. The tribological behavior of Al2O3 multilayer coatings was studied at room temperature using 24CrMoV5-1 balls; friction coefficients were comparable for both α- and κ-Al2O3 multilayer coatings. As a result of the relatively high hardness of coatings and the generation of abrasive wear particles, larger wear tracks were observed on balls. In Rockwell C tests, good adhesion at Al2O3/Ti(C,N)-based layer’s interface was reported in κ-Al2O3 multilayer coatings, which could be attributed to the deposition of κ-bonding layers consisting of needle-shaped grains. The cutting performances in the turning-roughing of 24CrMoV5-1 steel under different parameters—cutting speed, feed, and depth of cut—were investigated. Herein, κ-Al2O3 multilayer coatings showed the longest tool life, double of that of a commercial CVD Al2O3 multilayer coating. The results obtained could enrich the existing database for the development of prediction models of tool wear and machined surface quality and help improve tool performance for the machining of 24CrMoV5-1 steel.

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Transient multi-domain thermal modeling of interrupted cutting with coated tools

Karagüzel

2021

Int J Adv Manuf Technol

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Cyclic heat-up and damage-relevant substrate plastification of single- and bilayer coated milling inserts evaluated numerically

Cited by 27 publications

References 33 publications

20 Hz synchrotron X-ray diffraction analysis in laser-pulsed WC-Co hard metal reveals oscillatory stresses and reversible composite plastification

20 Hz synchrotron X-ray diffraction analysis in laser-pulsed WC-Co hard metal reveals oscillatory stresses and reversible composite plastification

Characteristics and Cutting Performance of CVD Al2O3 Multilayer Coatings Deposited on Tungsten Carbide Cutting Inserts in Turning of 24CrMoV5-1 Steel

Transient multi-domain thermal modeling of interrupted cutting with coated tools

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