Cutting Performance of Low Stress Thick TiAlN PVD Coatings during Machining of Compacted Graphite Cast Iron (CGI)
Source abstract
Abstract
A new family of physical vapor deposited (PVD) coatings is presented in this paper. These coatings are deposited by a superfine cathode (SFC) using the arc method. They combine a smooth surface, high hardness, and low residual stresses. This allows the production of PVD coatings as thick as 15 µm. In some applications, in particular for machining of such hard to cut material as compacted graphite iron (CGI), such coatings have shown better tool life compared to the conventional PVD coatings that have a lower thickness in the range of up to 5 μm. Finite element modeling of the temperature/stress profiles was done for the SFC coatings to present the temperature/stress profiles during cutting. Comprehensive characterization of the coatings was performed using XRD, TEM, SEM/EDS studies, nano-hardness, nano-impact measurements, and residual stress measurements. Application of the coating with this set of characteristics reduces the intensity of buildup edge formation during turning of CGI, leading to longer tool life. Optimization of the TiAlN-based coatings composition (Ti/Al ratio), architecture (mono vs. multilayer), and thickness were performed. Application of the optimized coating resulted in a 40–60% improvement in the cutting tool life under finishing turning of CGI.
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Research context
OpenAlex topics: Metal and Thin Film Mechanics · Advanced machining processes and optimization · Diamond and Carbon-based Materials Research
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
Affiliations
Materials Research Laboratory, Kobe Steel Ltd., Kobe 651-2271, Japan
McMaster Manufacturing Research Institute (MMRI), Department of Mechanical Engineering, McMaster University, Hamilton, ON L8S 4L7, Canada
Department of Mechanical and Materials Science, Catholic University of Santa Catarina, Joinville, SC 89203-005, Brazil
Micro Materials Ltd., Wrexham LL13 7YL, UK
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