FE temperature- and residual stress prediction in milling inserts and correlation with experimentally observed damage mechanisms

Nemetz, Andreas W.; Daves, Werner; Klünsner, Thomas; Ecker, Werner; Teppernegg, Tamara; Czettl, Christoph; Krajinović, Ivan

doi:10.1016/j.jmatprotec.2018.01.039

Cited by 38 publications

(6 citation statements)

References 23 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

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“…The position of these fine comb cracks depends on the stress distribution at the cutting-edge during cutting. It was reported experimentally and validated later by modeling that the build-up of important tensile stress in specific regions in the rake face coincide with the position of comb cracking [3,25]. As a consequence, fine comb cracks grow with damage and chipping around the cracks.…”

Section: Comb Crack Modelmentioning

confidence: 75%

“…To understand the observed difference in comb crack behavior, the mechanisms that lead to the formation of cracks were investigated. It has been experimentally reported and validated by modeling that the initiation of comb cracks in CVD coated inserts is connected to the CVD pre-crack network [24,25]. Furthermore, CVD cooling cracks in both rake and flank face network are considered to be the nucleus for the initiation of comb cracking as it is considered the most relevant defect that exists in the coating.…”

Section: Wear Studies-crackingmentioning

confidence: 99%

Design of Comb Crack Resistant Milling Inserts: A Comparison of Stresses, Crack Propagation, and Deformation Behavior between Ti(C,N)/α-Al2O3 and Zr(C,N)/α-Al2O3 CVD Coatings

Moreno¹,

Azhari²,

Apel³

et al. 2021

Crystals

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Investigations on comb crack resistance of milling inserts coated with chemical vapor deposition (CVD) Ti(C,N)/α-Al2O3 and Zr(C,N)/α-Al2O3 showed a distinct wear evolution in both systems. Wear studies revealed that the appearance of comb cracks is connected to the initial CVD cooling crack network. Micropillar compression tests indicated a brittle intergranular fracture mechanism for the Ti(C,N) layer and a transgranular fracture accompanied with signs of plastic deformation for the Zr(C,N) coating. Additionally, for the Zr(C,N) based system, a compressive stress condition in the temperature range of interest (200–600 °C) was determined by in-situ synchrotron X-ray diffraction. The set of residual compressive stresses together with the ability of the Zr(C,N) layer to deform plastically are key features that explain the enhanced resistance to comb crack wear of the Zr(C,N) based system in milling of cast iron.

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“…Contact loading appears in many engineering applications such as tools [1], screws [2], gears [3], crossing [4], shot peening and fretting [5] or a wheel/rail and twin-disc [6].…”

Section: Introductionmentioning

confidence: 99%

Design of the Machine Parts Subjected to Elastic-Plastic Contact Conditions

Kráčalík¹

2019

Research Papers Faculty of Materials Science and Technology Slovak University of Technology

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FE temperature- and residual stress prediction in milling inserts and correlation with experimentally observed damage mechanisms

Cited by 38 publications

References 23 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

Design of Comb Crack Resistant Milling Inserts: A Comparison of Stresses, Crack Propagation, and Deformation Behavior between Ti(C,N)/α-Al2O3 and Zr(C,N)/α-Al2O3 CVD Coatings

Design of the Machine Parts Subjected to Elastic-Plastic Contact Conditions

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