Improving the Efficiency of Metalworking by the Cutting Tool Rake Surface Texturing and Using the Wear Predictive Evaluation Method on the Case of Turning an Iron–Nickel Alloy

Abstract

The article proposes and substantiates the function of predictive evaluation using the criterion of the relative efficiency of using a cutting tool with a microtextured rake surface based on tangential force and cutting temperature. Comprehensive durability tests carried out under various processing modes with the measurement of heat power parameters made it possible to create an experimental base for mathematical modeling. An empirical model of cutting parameters based on modified multiplicative functions with non-constant indicators in the form of linear dependencies on processing factors was used based on planning an experiment for processing a heat-resistant alloy for predictive wear assessment in order to determine rational cutting modes. Predicting the rational use of a cutting tool with a microtextured work surface made it possible to obtain a 1.3-fold increase in durability.

The Study of Radius End Mills with TiB2 Coating When Milling a Nickel Alloy

“…Another promising direction is related to the texturing of functional surfaces, which improves cutting characteristics, ensuring the processing quality and affecting the wear degree due to changes in lubrication conditions. Tool durability increases due to reduced cutting forces and temperature, friction forces, and chemical activity of materials in the contact zone [ 5 ]. Although additional operations in the manufacture of the tool slightly increase its cost, the advantages of textured cutters and plates become evident in the cost of the workpiece [ 6 ].…”

Technologies of Coatings and Surface Hardening: Industrial Applications

“…The product's operational life can be improved via introduced innovations in the coating and surface layer structure deposed to such materials as high-speed tool steel [16], Al 2 O 3 + TiC ceramic [17,18], Si and hard alloy substrate [19][20][21][22][23][24][25], plastic substrate [26]. The innovative multilayer coatings demonstrate the destruction of the coating from the contact load passing through one layer and developing along the interface between the layers, significantly increasing the product's durability [19][20][21][22][23][24][25]. At the same time, nanocomposite coatings containing the amorphous phase with the introduced nano-crystallines of 3-5 nm hamper the development of the cracks and redirect them [23,24].…”

“…The innovative multilayer coatings demonstrate the destruction of the coating from the contact load passing through one layer and developing along the interface between the layers, significantly increasing the product's durability [19][20][21][22][23][24][25]. At the same time, nanocomposite coatings containing the amorphous phase with the introduced nano-crystallines of 3-5 nm hamper the development of the cracks and redirect them [23,24]. It is shown that annealing up to 1000 • C can transform an amorphous homogeneous coating structure into a nanocomposite one [18].…”

“…Thin oxide films of a few nanometers effectively hamper moisture and protect microelectronics from mechanical and thermal loads [26]. The quality of the surface where the coating is supposed to be deposed plays a critical role in the product's durability [17] when special measures can reduce the adhesion of the workpiece material and favor the descent of material flow on the tool face [24]. The questions of reliable coating deposition diagnostics remain open and require special measures [27].…”

“…Properties including high-temperature and triboproperties of the advanced multi- [19][20][21][22][23][24][25] and mono-layer [16,17], nanocomposite [23,24], nanostructured [18], and nanothin coatings [26];…”