Microstructural analysis of failure progression for coated carbide tools during high-speed milling of Ti-6Al-4V

Wang, Fuzeng; Ji, Kaixun; Guo, Ziyu

doi:10.1016/j.wear.2020.203356

Cited by 21 publications

(8 citation statements)

References 44 publications

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“…The direction of the friction speed should be the opposite direction of the projection of the movement speed on the common tangent plane. The common tangent plane could be solved by separately obtaining the partial derivatives of the two contact surfaces and then simultaneously solving the equations, as shown in equation (9). The unit direction vector projected by the movement speed on the common tangent plane can be expressed as equation (10) in the workpiece coordinate.…”

Section: Determination Of Friction Speedmentioning

confidence: 99%

“…At present, the measurement and characterization of the flank face friction of milling cutter tooth mainly focus on the maximum wear width, ignoring the characteristic information of the entire wear boundary of the flank face. Wang et al 9 examined the microstructure and compositional characterization of worn tool inserts using SEM and EDS analysis. Oliveira et al 10 tested different tools wear under finishing, roughing, and moderate machining conditions.…”

Section: Introductionmentioning

confidence: 99%

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Instantaneous friction energy consumption and its evolution of high energy efficiency milling cutter

Zhao

Zhang

Jiang

et al. 2022

Advances in Mechanical Engineering

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In the process of high-efficiency milling of titanium alloys, cutting vibration causes the frequent changes in the contact relationship between the flank face of the cutter tooth and the workpiece. The instantaneous friction speed, friction force and energy consumption of the milling cutter thus change continuously, resulting in the difficulty to precisely control the wear and life of milling cutter. This has become a bottleneck of restricting the further improvement of the cutting performance of high energy efficiency milling cutter. In this work, the model of instantaneous friction velocity and friction energy consumption of the flank face of the cutter tooth under vibration are developed. The distribution and evolution of instantaneous friction speed and friction energy consumption are studied. The proposed models are verified by high-efficiency milling experiments. The results show that the average relative error of the proposed model is 10.05%, by using this model, the influences of the cutting vibration on instantaneous friction energy consumption and friction wear boundaries could be effectively unveiled. The proposed model also could accurately describe the distribution and evolution of the above-mentioned parameters.

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Section: Determination Of Friction Speedmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Instantaneous friction energy consumption and its evolution of high energy efficiency milling cutter

Zhao

Zhang

Jiang

et al. 2022

Advances in Mechanical Engineering

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“…Having excellent performance, coated tools are widely used to cut various materials [ 8 , 9 , 10 ], accounting for 80% of the total tool count. Among them, Ti 1-x Al x N-coated tools are widely used in titanium alloy machining [ 11 , 12 , 13 ] due to their high heat resistance, superior chemical resistance, and low friction coefficient [ 14 , 15 ]. Therefore, extensive studies have been conducted on the performance and wear of Ti 1-x Al x N-coated tools.…”

Section: Introductionmentioning

confidence: 99%

Effect of Al Content on the Wear Evolution of Ti1-xAlxN-Coated Tools Milling Ti-6Al-4V Alloy

Fan

Zhang

et al. 2023

Micromachines

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Ti1-xAlxN coating is formed by replacing some Ti atoms in TiN with Al atoms, and their properties are closely related to Al content (0 < x < 1). Recently, Ti1-xAlxN-coated tools have been widely used in the machining of Ti-6Al-4V alloy. In this paper, the hard-to-machine material Ti-6Al-4V alloy is used as the study material. Ti1-xAlxN-coated tools are used for milling experiments. The evolution of the wear form and the wear mechanism of Ti1-xAlxN-coated tools are studied, and the influence of Al content (x = 0.52, 0.62) and cutting speed on tool wear are analyzed. The results show that the wear on the rake face changes from the initial adhesion and micro-chipping to coating delamination and chipping. Wear on the flank face varies from the initial adhesion and grooves to boundary wear, build-up layer, and ablation. The main wear mechanisms of Ti1-xAlxN-coated tools are dominated by adhesion, diffusion, and oxidation wear. Ti0.48Al0.52N coating protects the tool well and extends its service life.

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“…Although a single-layer coating can improve the cutting performance of carbide tools, there are disadvantages such as poor bonding, lower hardness and rougher surface. Some scholars found that composite-coated carbide tools have a better machining quality compared to single-coated carbide tools [ 11 , 12 ]. Multi-layer composite coatings with high hardness, high corrosion resistance and high wear resistance are widely used and have gradually attracted researchers’ attention.…”

Section: Introductionmentioning

confidence: 99%

Optimization of AlCrSiWN Coating Process Parameters and Performance Study by the Matrix Analysis Method

et al. 2022

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An AlCrSiWN coating was prepared on a cemented carbide substrate by the arc ion plating technology. The optimization of the coating process was carried out by matrix analysis of orthogonal experiments to calculate the influence of the process parameters on the hardness, bonding and roughness indexes of the coating, determine the optimal coating process parameters, and focus on the influence of the bias voltage on the microscopic morphology, mechanical properties and friction properties of the coating. The results showed that the influence of the process parameters on the indexes of the orthogonal experiments was in the following order: bias voltage > arc current > N2 flow rate. The optimal solution was achieved with an arc current of 160 A, a bias voltage of −80 V, and a N2 flow rate of 600 sccm. Properly increasing the bias voltage improved the microscopic morphology, mechanical properties and wear resistance of the coating. When the bias voltage was −80 V, the coating surface presented fewer large particles with a less uniform size and no obvious crater defects; in addition, the cross-sectional structure changed from grape-like to columnar, and the coating had higher hardness, lower roughness and better bond strength. In the friction performance test, coating at a −80 V bias voltage showed better wear resistance, which was reflected in lower friction coefficient and wear, and the wear mechanism mainly consisted of adhesion and oxidation wear.

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Microstructural analysis of failure progression for coated carbide tools during high-speed milling of Ti-6Al-4V

Cited by 21 publications

References 44 publications

Instantaneous friction energy consumption and its evolution of high energy efficiency milling cutter

Instantaneous friction energy consumption and its evolution of high energy efficiency milling cutter

Effect of Al Content on the Wear Evolution of Ti1-xAlxN-Coated Tools Milling Ti-6Al-4V Alloy

Optimization of AlCrSiWN Coating Process Parameters and Performance Study by the Matrix Analysis Method

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