Performance of Al2O3/TiC mixed ceramic inserts coated with TiAlSiN, WC/C and DLC thin solid films during hard turning of AISI 52100 steel

Kumar, Ch Sateesh; Patel, Saroj Kumar; Fernandes, Filipe

doi:10.1016/j.jmrt.2022.06.092

Cited by 8 publications

(3 citation statements)

References 33 publications

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“…Notably, mixed ceramics' significance in hard turning was emphasized by the various authors, showcasing its effectiveness in highstrength steel and ultra-high-strength steel turning. For example, Kumar et al [16] evaluated the turning performance of Al2O3/TiC mixed ceramic cutting inserts with TiAlSiN coating in hard turning. Grzesik [17] also explored wear mechanisms in the turning of high-strength steel using Al 2 O 3 + TiC mixed ceramic tools.…”

Section: The Experimental Proceduresmentioning

confidence: 99%

Mathematical Modeling of the Bearing Ratio Curve Rmr (50% Rz), through Investigation of the Effect of Process Parameters in Hard Turning of Steel C55 (DIN) with Mixed Ceramics MC2 (Al2O3 + TiC)

Shabani,

Tomov

2024

Advances in Tribology

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The subject of modeling and predicting roughness parameters in hard machining has been discussed in many literature sources. However, most of these sources cover only the amplitude parameters such as Ra and Rz, leaving it unexplored to the right extent compared to its importance the roughness parameter bearing ratio curve (the Abbott–Firestone curve) which is essential in understanding the actual contact area of mating surfaces. To bridge this gap, this research has developed a mathematical model using the design of experiments method through investigation of the effect of process parameters in hard turning of Steel C55 (DIN) with mixed ceramics MC2 (Al2O3 + TiC). The model predicts the bearing ratio curve parameter Rmr (50% Rz), statistically processed using CADEX and Matlab. The research includes the ANOVA as a complementary tool in validating the generated mathematical model. The research analyzes the effects of material properties, cutting forces, and tool geometry as factors that affect the machining process. Additionally, it emphasizes the robustness of hard turning in consistently producing waviness patterns. Overall, this research provides valuable insights into the predictable effects of parameters on machined surfaces, which contributes to a better understanding of surface finish in metalworking.

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Section: The Experimental Proceduresmentioning

confidence: 99%

Mathematical Modeling of the Bearing Ratio Curve Rmr (50% Rz), through Investigation of the Effect of Process Parameters in Hard Turning of Steel C55 (DIN) with Mixed Ceramics MC2 (Al2O3 + TiC)

Shabani,

Tomov

2024

Advances in Tribology

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“…Since Aisenberg et al synthesized DLC films using low-energy carbon ion beam, hard hydrogen-free DLC films have drawn an intensive attention due to their high hardness, smooth surface, and good corrosion resistance [1][2][3][4][5]. The hard DLC films present a broad prospect as a good tribological film in the green precision manufacturing industry [6][7][8][9]. The industry demands urge the DLC films to have both high hardness and high toughness.…”

Section: Introductionmentioning

confidence: 99%

Toughness Characterization and Toughening Mechanism of Diamond-like Carbon Films

Yu,

Wang,

Hou

et al. 2023

Preprint

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Diamond-like carbon (DLC) films have a promising tribological application in green precision manufacturing, but their toughness represents a serious issue in the way of their application perspective. The film thickness is on the micrometer scale and makes conventional methods unsuitable for its toughness characterization. The absence of an accepted method for characterizing the DLC toughness has hindered the related research on the development of toughening methods and understanding the mechanism. This work intends to explore a relatively simple and acceptable characterization method to measure the film toughness. Moreover, toughening mechanisms of DLC films are proposed during the characterization to reveal the toughening mechanism. The toughness can be fully characterized through combining impact toughness and scratch toughness. The impact toughness can be obtained by observing the size of the indentation and the crack state around the indentation in the impact experiment. The scratch toughness could be assessed by combining the scratch morphology and Crack Propagation Resistance (CPRS). The improvement of film toughness should be carried out from two aspects: preventing microcrack initiation and suppressing crack propagation. Appropriate doping of non-carbide metal particles can effectively improve the toughness of the film, and there are seven main factors affecting the toughening of the film. Five toughening mechanisms of non-carbide metals from film preparation to test stage are revealed during the investigation of the change patterns.

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“…It is also known that high temperature and other severe conditions at the interface between the cutting edge and chip are the main reasons for wear and failures of ceramic tools [9]. Thus, due to continuous development of engineering materials and the increasing demand for machining motivates to continue research and especially to investigate new materials for cutting tools [10].…”

Section: Introductionmentioning

confidence: 99%

Study in durability of Cr₂O₃-based ceramic cutting tools

Siemiątkowski

Morozow

Rucki

et al. 2023

22nd International Scientific Conference Engineering for Rural Development Proceedings

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The research was performed in the context of feasibility examinations of chromia application as cutting tool materials. In the paper, a study on the Cr2O3 –based ceramic cutting tools is presented from the perspective of structural features and durability under various machining parameters. Comparative analysis was performed using alumina-based ceramic cutting inserts. Microstructure was examined using scanning and transmission electron microscopy (SEM and TEM), LEO1455 VP (ZEISS) and MIRA3 TESCAN, respectively. It was found that Cr2O3 –based ceramic with AlN additions after electroconsolidation exhibited more fine structure with evenly distributed AlN inclusions and small amount of spherical pores, below 2%. The cutting durability tests were performed with both hardened NC11LV and non-hardened C45 (1.0503) steels, using multiedge cutting inserts of dimensions 14.75 mm × 14.75 mm × 4.75 mm, made of respective ceramics. The machine tool Mazak QTE was used for the tests, and the wear criterion was 0.4 mm notch wear value, assessed with Keyence microscope. It was demonstrated that a pure alumina cutting tool exhibited 3 times larger wear than Cr2O3–AlN one after 25 minutes of work. On the other hand, Cr2O3–AlN cutting edge reached the same wear rate at 175 m·min-1 as Al2O3 –based tools at just 50 m·min-1. For the same cutting speed of 150 m·min-1, the chromia-based ceramic insert worked over 30 minutes, two times longer than alumina ones. The increased wear resistance and durability can be attributed to the fine-dispersed structure obtained not only by certain proportion of components, but also by the electroconsolidation technique with specific parameters.

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Performance of Al2O3/TiC mixed ceramic inserts coated with TiAlSiN, WC/C and DLC thin solid films during hard turning of AISI 52100 steel

Cited by 8 publications

References 33 publications

Mathematical Modeling of the Bearing Ratio Curve Rmr (50% Rz), through Investigation of the Effect of Process Parameters in Hard Turning of Steel C55 (DIN) with Mixed Ceramics MC2 (Al2O3 + TiC)

Mathematical Modeling of the Bearing Ratio Curve Rmr (50% Rz), through Investigation of the Effect of Process Parameters in Hard Turning of Steel C55 (DIN) with Mixed Ceramics MC2 (Al2O3 + TiC)

Toughness Characterization and Toughening Mechanism of Diamond-like Carbon Films

Study in durability of Cr₂O₃-based ceramic cutting tools

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Performance of Al2O3/TiC mixed ceramic inserts coated with TiAlSiN, WC/C and DLC thin solid films during hard turning of AISI 52100 steel

Cited by 8 publications

References 33 publications

Mathematical Modeling of the Bearing Ratio Curve Rmr (50% Rz), through Investigation of the Effect of Process Parameters in Hard Turning of Steel C55 (DIN) with Mixed Ceramics MC2 (Al2O3 + TiC)

Mathematical Modeling of the Bearing Ratio Curve Rmr (50% Rz), through Investigation of the Effect of Process Parameters in Hard Turning of Steel C55 (DIN) with Mixed Ceramics MC2 (Al2O3 + TiC)

Toughness Characterization and Toughening Mechanism of Diamond-like Carbon Films

Study in durability of Cr2O3-based ceramic cutting tools

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Study in durability of Cr₂O₃-based ceramic cutting tools