The Role of Thin-Film Vacuum-Plasma Coatings and Their Influence on the Efficiency of Ceramic Cutting Inserts
Source abstract
Abstract
The main problem with ceramics used in cutting tools is related to the unpredictable failures caused by the brittle fracturing of ceramic inserts, which is critical for the intermittent milling of cyclic loading. A 125-mm-diameter eight-toothed end mill, with a mechanical fastening of ceramic inserts, was used as a cutting tool for milling hardened steel (102Cr6). For the experiments, square inserts of the Al2O3 + SiC ceramic were used and compared with the samples made of Al2O3 + TiC to confirm the obtained results. The samples were coated with diamond-like coating (DLC), TiZrN, and TiCrAlN coatings, and their bending strength and adhesion were investigated. Investigations into the friction coefficient of the samples and operational tests were also carried out. The effect of smoothing the microroughness and surface defects in comparison with uncoated inserts, which are characteristic of the abrasive processing of ceramics, was investigated and analyzed. The process developed by the authors of the coating process allows for the cleaning and activation of the surface of ceramic inserts using high-energy gas atoms. The impact of these particles on the cutting edge of the insert ensures its sharpening and reduces the radius of curvature of its cutting edges.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: Advanced materials and composites · Metal and Thin Film Mechanics · Advanced ceramic materials synthesis
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
Affiliations
Department of High-efficiency Machining Technologies, Moscow State University of Technology STANKIN, Moscow 127055, Russia
Funding
Ministry of Education and Science of the Russian Federation
References (50)
Show source-provided references
1. Nanostructured coatings for tooling applications10.1016/j.ijrmhm.2016.06.017 ↗
2. Delamination and longitudinal cracking in multi-layered composite nanostructured coatings and their influence on cutting tool life10.1016/j.wear.2017.07.021 ↗
3. Development of wear-resistant complex for high-speed steel tool when using process of combined cathodic vacuum arc deposition10.1016/j.procir.2013.06.159 ↗
4. Li, L., Sun, L., Liu, C., Wang, X.H., Wang, X.Z., and Zhang, J. (2017). Microstructure and properties of porous Si3N4/dense Si3N4 joints bonded using RE-Si-Al-O-N (RE = Y or Yb) glasses. Metals, 7.10.3390/met7110500 ↗
5. Bai, Y., Wang, Z., Li, X., Huang, G., Li, C., and Li, Y. (2018). Microstructure and mechanical properties of Zn-Ni-Al2O3 composite coatings. Materials, 11.10.3390/ma11050853 ↗
6. Song, C., Wang, S., Liu, J., and Zhai, S. (2018). Microstructure and mechanical properties of Al2O3/Er3Al5O12 binary eutectic ceramic prepared by bridgman method. Materials, 11.10.3390/ma11040534 ↗
7. HPHT sintering of binderless Si3N4: Structure, microstructure, mechanical properties and machining behavior10.1007/s40430-018-1035-6 ↗
8. Cutting with coated tools: Coating technologies, characterization methods and performance optimization10.1016/j.cirp.2012.05.006 ↗
9. Development and application of coated ceramic cutting tools10.4028/www.scientific.net/AST.45.1155 ↗
10. Tool life and wear mechanism of coated and uncoated Al2O3/TiCN mixed ceramic tools in turning hardened alloy steel10.1016/j.wear.2011.11.010 ↗
11. Shabani, M., Sacramento, J., Oliveira, F.J., and Silva, R.F. (2017). Multilayer CVD diamond coatings in the machining of an Al6061-15 vol % Al2O3 composite. Coatings, 7.10.3390/coatings7100165 ↗
12. Surface roughness analysis for economical feasibility study of coated ceramic tool in hard turning operation10.1007/s41660-017-0019-9 ↗
13. Surface roughness analysis of hardened steel using TiN coated ceramic inserts
14. Microstructure of TiAlN and CrAlN coatings and cutting performance of coated silicon nitride inserts in cast iron turning10.1016/j.ceramint.2014.02.083 ↗
15. Vacuum-arc multilayer nanostructured TiN/Ti coatings: Structure, stress state, properties10.1007/s11041-012-9451-1 ↗
16. Tribological properties of the PVD and CVD coatings deposited onto the nitride tool ceramics10.1016/j.jmatprotec.2005.04.032 ↗
17. Pimentel, J.V., Klemm, R., Dalgic, M., Irretier, A., and Krieger, K.L. (2017). Automatic detection of fractures during tensile testing using vibroacoustic sensors. Proceedings, 1.10.3390/ecsa-3-P001 ↗
18. Technical diagnostics functioning machines and mechanisms10.1088/1757-899X/312/1/012012 ↗
19. Measurement of spatial vibrations for diagnostics of the performance of a set of spindle assemblies10.1007/s11018-017-1134-2 ↗
20. Huo, D., Chen, W., and Teng, X. (2017). Modeling the influence of tool deflection on cutting force and surface generation in micro-milling. Micromachines, 8.10.3390/mi8060188 ↗
21. Study of milling speed effect on uneven fields of stress, strain, strain rate and temperature in the processing of hardened steel SKD1110.1166/sam.2017.3113 ↗
22. Estimation of local plastic deformation in cutting zone during turning10.4028/www.scientific.net/KEM.662.173 ↗
23. Investigation on affecting factors of vibration in milling harden steel assembled with different hardness10.4028/www.scientific.net/KEM.546.137 ↗
24. Experiment research of cutter edge and cutting parameters influence on machined surface roughness for high speed milling hardened steel10.4028/www.scientific.net/AMR.670.70 ↗
25. Ali, M.S., Hanim, M.A.A., Tahir, S.M., Jaafar, C.N.A., Mazlan, N., and Amin Matori, K. (2017). The effect of commercial rice husk ash additives on the porosity, mechanical properties, and microstructure of alumina ceramics. Adv. Mater. Sci. Eng., 2586026.10.1155/2017/2586026 ↗
26. A nitride whisker template for growth of mullite in SiC reticulated porous ceramics10.1016/j.ceramint.2017.05.169 ↗
27. Effect of silicon on properties of Al2O3-SiCw composite ceramics in-situ synthesized by aluminium-assisted carbothermal reduction of coal series kaolin for solar thermal storage10.1016/j.jallcom.2016.09.107 ↗
28. Synthesis and characterization of alumina (Al2O3) nanoparticles prepared by a simple sol-gel method
29. Synthesis and characterization of Al2O3-SiC nano composite by sol-gel method and the effect of TiO2 on sintering10.4028/www.scientific.net/JNanoR.13.7 ↗
30. High temperature composites SiC-Al2O3-ceramics with Al2O3-matrix
31. Microstructure and high-temperature mechanical properties of ZrO2-Al2O3-SiC ceramics10.1007/s11665-015-1650-7 ↗
32. Preparation of SiCw/Al2O3 composite sheets through gel-tape-casting process10.4028/www.scientific.net/MSF.675-677.119 ↗
33. Kumar, R., Chaubey, A.K., Maity, T., and Prashanth, K.G. (2018). Mechanical and tribological properties of Al2O3-TiC composite fabricated by spark plasma sintering process with metallic (Ni, Nb) binders. Metals, 8.10.3390/met8010050 ↗
34. Shalaby, M., and Veldhuis, S. (2018). New observations on high-speed machining of hardened AISI 4340 steel using alumina-based ceramic tools. J. Manuf. Mater. Process., 2.10.3390/jmmp2020027 ↗
35. Yuan, J., Boyd, J.M., Covelli, D., Arif, T., Fox-Rabinovich, G.S., and Veldhuis, S.C. (2016). Influence of workpiece material on tool wear performance and tribofilm formation in machining hardened steel. Lubricants, 4.10.3390/lubricants4020010 ↗
36. Effect of electric current on densification behavior of conductive ceramic powders consolidated by spark plasma sintering10.1016/j.actamat.2017.11.010 ↗
37. Design and fabrication of gradient cermet composite cutting tool, and its cutting performance10.1016/j.jallcom.2017.10.187 ↗
38. Aimable, A., Doubi, H.G., Stuer, M., Zhao, Z., and Bowen, P. (2017). Synthesis and sintering of ZnO nanopowders. Technologies, 5.10.20944/preprints201704.0089.v1 ↗
39. Sinescu, C., Bradu, A., Duma, V.-F., Topala, F., Negrutiu, M., and Podoleanu, A.G. (2017). Effects of temperature variations during sintering of metal ceramic tooth prostheses investigated non-destructively with optical coherence tomography. Appl. Sci., 7.10.3390/app7060552 ↗
40. Hardening of a surface of products of the complex geometrical shape in a mixture of a metallic vapour and fast molecules of gas
41. Gas discharge source of metal vapor and fast gas atoms10.1134/S0020441213030044 ↗
42. Cutting tools made of layered composite ceramics with nanoscale multilayered coatings10.1016/j.procir.2012.04.054 ↗
43. Nano-scale multi-layered coatings for improved efficiency of ceramic cutting tools10.1007/s00170-016-9353-2 ↗
44. Ciniero, A., Le Rouzic, J., and Reddyhoff, T. (2017). The use of triboemission imaging and charge measurements to study DLC coating failure. Coatings, 7.10.3390/coatings7080129 ↗
45. Silva, F., Martinho, R., Andrade, M., Baptista, A., and Alexandre, R. (2017). Improving the wear resistance of moulds for the injection of glass fibre-reinforced plastics using PVD coatings: A comparative study. Coatings, 7.10.3390/coatings7020028 ↗
46. Effect of bias on the structure and properties of TiZrN thin films deposited by unbalanced magnetron sputtering10.1016/j.tsf.2016.05.021 ↗
47. Local atomic structures and degradation behaviors of Ti1−xZrxN coatings under laser thermal shock10.1016/j.matchar.2017.07.003 ↗
48. Decomposition and phase transformation in TiCrAlN thin coatings10.1116/1.4757953 ↗
49. The effects of deposition temperature and post-annealing on the crystal structure and mechanical property of TiCrAlN films with high Al contents10.1016/j.surfcoat.2005.03.013 ↗
50. Focused beams of fast neutral atoms in glow discharge plasma10.1063/1.4985249 ↗