Investigation on the performance of AlCrN and AlTiN coated cemented carbide inserts during end milling of maraging steel under dry, wet and cryogenic environments

Varghese, Vinay; Akhil, K.T.; Рамеш, М. Р.; Chakradhar, D.

doi:10.1016/j.jmapro.2019.05.021

Cited by 59 publications

(24 citation statements)

References 26 publications

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“…This method as showed great results in terms of tool life when compared to conventional cooling methods or dry machining [74]. In the work performed by Varghese et al [75], it is investigated the performance of AlCrN and AlTiN coated cemented carbide tools during the end mill of MDN 250 maraging steel under dry, wet and cryogenic lubrication conditions. The coatings proved to be a significant improvement on the machinability, by extending tool life, obtaining better surface finish and overall reducing the cutting forces developed during the milling process.…”

Section: Coated Tools Behavior Under Advanced Cutting and Lubricationmentioning

confidence: 99%

Recent Advances on Coated Milling Tool Technology—A Comprehensive Review

Sousa

Silva

2020

Coatings

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The milling process is one of the most used processes in the manufacturing industry. Milling, as a process, as evolved, with new machines and methods being employed, in order to obtain the best results consistently. Milling tools have also seen quite an evolution, from the uncoated high-speed steel tool, to the now vastly used, coated tools. Information on the use of these coated tools in recent scientific researches was collected. The coatings that are currently being researched are going to be presented, highlighting some novel advances in the nanocomposite and diamond coatings area, as these coatings are seeing a growing use in the industry, with very satisfactory results, with performance and tool-life increase. Wear mechanism of various types of coatings are also a popular topic on recent research, as the cutting behavior of these coated tools provides valuable information on the tool’s-life. Furthermore, analysis of these mechanisms enables for the selection of the best coating type for the correct application. Recently, the employment of coated tools paired with sustainable lubrication methods as seen some use. As this presents the opportunity to enhance the coated tool’s and the process’s performance, obtaining better results, in terms of better tool-life and better surface finish quality, in a more sustainable fashion.

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Section: Coated Tools Behavior Under Advanced Cutting and Lubricationmentioning

confidence: 99%

Recent Advances on Coated Milling Tool Technology—A Comprehensive Review

Sousa

Silva

2020

Coatings

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“…This ratio is sometimes considered as a possible indicator of wear resistance [17]. The calculated ratios are slightly above the value of 0.06 reported by Varghese et al for AlCrN but smaller than the value of 0.09 found by Romero et al for CrAlN films [18,19]. Figure 1 shows the end of sliding tracks after scratch testing.…”

Section: Residual Stress Analysismentioning

confidence: 56%

Phase and Residual Stress Evaluation of Dual-Phase Al70Cr30N and Al80Cr20N PVD Films

Kohlscheen

Shibata

2019

Crystals

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We investigated arc ion-plated Al70Cr30N and Al80Cr20N thin films deposited with three different bias voltages (50 V, 100 V, and 150 V) to study crystal phase stabilities, residual stresses, and mechanical properties. Commercial compositions of AlxCr100–xN coatings typically range from x = 50 to 70 where the cubic face centered crystal phase occurs. The present study focuses on films near the solubility limit of Al in the cubic Cr(Al)N lattice around 70 at.%, above which hexagonal AlN (h–AlN) starts to form in significant amounts. Residual stress values are obtained by two methods: grazing incidence diffraction with the wholepattern fitting and the conventional side inclination method (sin2Ψ method). When multiple phases are present in the film, wholepattern fitting turns out to be particularly effective and a comparison of both measurement methods will be discussed. The Al70Cr30N films consist of the cubic phase with crystallite sizes of about 70 nm for all bias voltages. Compressive stress increased with bias voltage from about 3 to almost 6 GPa and coatings become brittle. Al80Cr20N films showed a different dependence on bias voltage. Using 50 V bias voltage in deposition, the major phase is h–AlN phase with a crystallite grain size of < 30 nm and (0002) preferred orientation. With increasing bias the cubic phase is stabilized also reaching about 70 nm crystallite size. In general, the compressive residual stress was significantly lower than for Al70Cr30N films for the same bias voltages which may be a result of the presence of the hexagonal phase. Wear and scratch tests confirmed higher ductility of the Al80Cr20N variants but reduced resistance of the films in impact wear testing.

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“…This methodology reduces the physical hardness of the workpiece, making it more compliant to cutting by reducing the specific cutting energy (i.e., the work done by the tool in removing a unit volume of the material). [47]; (c) schematic diagram to illustrate the mechanism of vibration-assisted machining [48].…”

Section: Advanced Machining Techniquesmentioning

confidence: 99%

“…Cryogenic cooling has been executed in cutting operations in different ways by using liquid nitrogen for precooling the workpiece, cooling the chip, and cooling the cutting tool and cutting zone [51]. Numerous studies have compared conventional cutting strategies and cryogenic cooling [47]; (c) schematic diagram to illustrate the mechanism of vibration-assisted machining [48].…”

Section: Cryogenic Machiningmentioning

confidence: 99%

The Critical Raw Materials in Cutting Tools for Machining Applications: A Review

et al. 2020

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A variety of cutting tool materials are used for the contact mode mechanical machining of components under extreme conditions of stress, temperature and/or corrosion, including operations such as drilling, milling turning and so on. These demanding conditions impose a seriously high strain rate (an order of magnitude higher than forming), and this limits the useful life of cutting tools, especially single-point cutting tools. Tungsten carbide is the most popularly used cutting tool material, and unfortunately its main ingredients of W and Co are at high risk in terms of material supply and are listed among critical raw materials (CRMs) for EU, for which sustainable use should be addressed. This paper highlights the evolution and the trend of use of CRMs) in cutting tools for mechanical machining through a timely review. The focus of this review and its motivation was driven by the four following themes: (i) the discussion of newly emerging hybrid machining processes offering performance enhancements and longevity in terms of tool life (laser and cryogenic incorporation); (ii) the development and synthesis of new CRM substitutes to minimise the use of tungsten; (iii) the improvement of the recycling of worn tools; and (iv) the accelerated use of modelling and simulation to design long-lasting tools in the Industry-4.0 framework, circular economy and cyber secure manufacturing. It may be noted that the scope of this paper is not to represent a completely exhaustive document concerning cutting tools for mechanical processing, but to raise awareness and pave the way for innovative thinking on the use of critical materials in mechanical processing tools with the aim of developing smart, timely control strategies and mitigation measures to suppress the use of CRMs.

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Investigation on the performance of AlCrN and AlTiN coated cemented carbide inserts during end milling of maraging steel under dry, wet and cryogenic environments

Cited by 59 publications

References 26 publications

Recent Advances on Coated Milling Tool Technology—A Comprehensive Review

Recent Advances on Coated Milling Tool Technology—A Comprehensive Review

Phase and Residual Stress Evaluation of Dual-Phase Al70Cr30N and Al80Cr20N PVD Films

The Critical Raw Materials in Cutting Tools for Machining Applications: A Review

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