Machinability Performance Investigation of TiAlN‐, DLC‐, and CNT‐Coated Tools during Turning of Difficult‐to‐Cut Materials

Abstract

Titanium alloy-based components are now attracted by the industries with their distinguished properties even though they are difficult to machine. The tooling industries encounter numerous problems in machining these metals like higher tool wear, huge volumes of cutting fluid consumption, and shorter tool life. The objective of this research is to enhance the surface of the cutting tool with carbon nanotube (CNT) deposition to solve the aforementioned difficulties. This research used the plasma-enhanced chemical vapor deposition method to coat CNT on high-speed steel tools. Microstructural investigations were performed using a scanning electron microscope and a Raman spectroscopic technique to ensure the homogenous deposition of CNT. Additionally, scratch testing was also conducted to assess the adhesive strength of the deposited layer to the substrate. Finally, the machining performance of the CNT-coated tool was compared with commercially available diamond-like carbon (DLC) and titanium aluminum nitride (TiAlN)-coated tools. Machining experiments conducted under three distinct cutting levels revealed that the CNT-deposited tool is appropriate for turning more challenging materials. CNT-coated tools showed substantial decreases in cutting tooltip temperature, turning forces, and tool wear compared to DLC and TiAlN-coated tools. In particular, tool life studies conducted under elevated machining circumstances recorded the enhancement in tool life as 96.3% and 26.8% in comparison with TiAlN and DLC, respectively.

Surface Enhancement of Titanium-Based Coatings on Commercial Hard Steel Cutting Tools

“…They reduce tool-chip friction and interactions, thereby increasing cost-effectiveness and machining output. A study by Vannan et al further supports these claims, demonstrating that tools coated with an AlCrN and TiAlN bilayer obtained a 50% reduction in machining duration, 580% longer life, a 130% harder surface, and 36% finer surface roughness when compared to an uncoated tool [26].…”

Performance assessment of vegetable based additive enriched cutting fluid for eco-friendly machining environment

“…The machinability performance is greatly affected by the development of cutting forces. The development of cutting forces like tangential force (FZ), feed force (FX) and radial force (Fy) at a higher level is not only due to the cutting parameters but also the friction that exists between the tool and workpiece interface (Chenrayan, Manivannan et al 2022). It can be vivid from the experiment results that all three cutting forces, namely FX, FY, and FZ observed at optimum experimental runs are 7.2, 4.5 and 5.65 times lesser than the cutting forces observed at experimental run 1.…”

Finite Element Analysis of Solid and Hollow Roller Bearings to Predict the Influence of Contact Factors on Cage Slip

“…Problems in the manufacturing industry have been related to tribology since the commencement of industrialisation. The use of tribology principles in various sectors to address intricate issues has increased dramatically in recent years [1][2][3][4][5][6]. Having a greater load carrying capability over ball bearings and being more adapted for higher speed environments than other types of roller bearings, cylindrical roller bearings find extensive use in a variety of industrial applications.…”