Hard turning using HiPIMS-coated carbide tools: Wear behavior under dry and minimum quantity lubrication (MQL)

Chinchanikar, Satish; Choudhury, S.K.

doi:10.1016/j.measurement.2014.06.002

Cited by 114 publications

(37 citation statements)

References 36 publications

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“…Vast studies of environmentally friendly processes confirmed that compared to dry cutting and flood cooling methods, the MQL and MQCL methods reduce tool wear (Ref 3,17), temperature (Ref 13) 25) studied effect of changes in the microstructure of the AISI 1045 steel in the tool-workpiece contact zone on the diffusion wear depending on the variable cutting speed during the turning. Studies have shown that the largest changes in the structure occur above 367 m/min due to dynamic recrystallization.…”

Section: Introductionmentioning

confidence: 99%

Structural and Microhardness Changes After Turning of the AISI 1045 Steel for Minimum Quantity Cooling Lubrication

Maruda

Królczyk

Michalski

et al. 2016

J. of Materi Eng and Perform

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This work presents the cooling effect under minimum quantity cooling lubrication and dry cutting on structural changes and microhardness of the ferritic-pearlitic AISI 1045 steel after turning. Due to the fact that the AISI 1045 steel has a two-phase structure, microhardness tests using the Vickers method were conducted with a load of 0.05 HV separately for ferrite and pearlite grains. The tests showed that cooling of the cutting zone under minimum quantity cooling lubrication (MQCL) condition decreased the depth of the hardened layer compared to dry cutting by approximately 40% for both pearlite and ferrite. Scanning electron microscopy analysis revealed that applying MQCL limits the formation of plastic deformations, among others, by reducing the surface crumple zone by approximately 50% compared to dry cutting. As a result of cooling being applied to the cutting zone using the MQCL method, the average diameter of ferrite grains has been decreased in the entire surface area compared to dry cutting. When using dry cutting, clear structural changes of the surface layer were also observed. This may be the result of sulfide inclusions which have formed, causing microcracks on the edge of the hardened layer and surface deformation visible as notches.

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Section: Introductionmentioning

confidence: 99%

Structural and Microhardness Changes After Turning of the AISI 1045 Steel for Minimum Quantity Cooling Lubrication

Maruda

Królczyk

Michalski

et al. 2016

J. of Materi Eng and Perform

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show abstract

“…As expected, the nitride coatings greatly increased the surface wear behavior [53]. Nevertheless, from XPS analyses, the formation of an oxide layer was detected after the burner rig test.…”

Section: Resultsmentioning

confidence: 59%

Thermal Shock and Oxidation Behavior of HiPIMS TiAlN Coatings Grown on Ti-48Al-2Cr-2Nb Intermetallic Alloy

et al. 2016

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A High Power Impulse Magnetron Sputtering (HiPIMS) method for depositing TiAlN environmental barrier coatings on the surface of Ti-48Al-2Cr-2Nb alloy was developed in view of their exploitation in turbine engines. Three differently engineered TiAlN films were processed and their performance compared. Bare intermetallic alloy coupons and coated specimens were submitted to thermal cycling under oxidizing atmosphere up to 850 °C or 950 °C, at high heating and cooling rates. For this purpose, a burner rig able to simulate the operating conditions of the different stages of turbine engines was used. Microstructures of the samples were compared before and after each test using several techniques (microscopy, XRD, and XPS). Coating-intermetallic substrate adhesion and tribological properties were investigated too. All the TiAlN films provided a remarkable increase in oxidation resistance. Good adhesion properties were observed even after repeated thermal shocks. HiPIMS pretreatments of the substrate surfaces performed before the coating deposition significantly affected the oxidation rate, the oxide layer composition and the coating/substrate adhesion.

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“…Also, model accuracy can be further improved by considering the effect of increase in cutting temperature with the progress in tool wear. It has been widely reported that cooling techniques improve the tool life and, to some extent, lowers the cutting forces [39]. However, modeling of worn tool cutting forces under different cooling techniques during hard turning is hardly been reported in the open literature.…”

Section: Worn Tool Cutting Forcesmentioning

confidence: 99%

Cutting force modeling considering tool wear effect during turning of hardened AISI 4340 alloy steel using multi-layer TiCN/Al2O3/TiN-coated carbide tools

Chinchanikar¹,

Choudhury

2015

Int J Adv Manuf Technol

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This study attempts to develop a cutting force model under oblique cutting conditions considering tool wear effect during turning of hardened steel with coated carbide tools to address metal cutting issues such as tool life, dimensional accuracy, and surface finish. Forces in worn out tool have been modeled by summing up forces in sharp tool and the forces due to flank wear alone. Waldorf's orthogonal force modeling approach is extended to 3-D cutting force analysis to model cutting forces due to flank wear alone. Forces in sharp tool and average interface temperature generated during machining are modeled using regression analysis. Shear flow stress, shear angle, and other model prerequisites are determined using equivalent cutting edge geometry in place of the actual cutting edge of tools having nose radius. Worn tool cutting force model is validated in turning of hardened AISI 4340 steel at different levels of hardness 35 and 45 HRC, respectively, using multi-layer TiCN/Al 2 O 3 /TiN-coated carbide tools. The quantitative agreement between experimental result and that of a developed model of worn tool cutting forces is favorably good with an average error of less than ±5 % with a maximum error of 11 %, which showed that the developed model is reliable and could be used effectively for predicting the forces in worn out tool within the domain of the cutting parameters.

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Hard turning using HiPIMS-coated carbide tools: Wear behavior under dry and minimum quantity lubrication (MQL)

Cited by 114 publications

References 36 publications

Structural and Microhardness Changes After Turning of the AISI 1045 Steel for Minimum Quantity Cooling Lubrication

Structural and Microhardness Changes After Turning of the AISI 1045 Steel for Minimum Quantity Cooling Lubrication

Thermal Shock and Oxidation Behavior of HiPIMS TiAlN Coatings Grown on Ti-48Al-2Cr-2Nb Intermetallic Alloy

Cutting force modeling considering tool wear effect during turning of hardened AISI 4340 alloy steel using multi-layer TiCN/Al2O3/TiN-coated carbide tools

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