A Comparative Study on the Wear Mechanisms of Uncoated and TiAlTaN-Coated Tools Used in Machining AMPCO® Alloy
Source abstract
Abstract
A consistent evolution in materials developed for the industry and chip-start cutting processes has been acknowledged over the years. Cutting tool improvement through applying advanced coatings has proven very effective, enabling tool life (TL) extension while ensuring better surface quality. TiAlTaN coating enhances TL and surface quality in machining processes. However, only minimal research has been dedicated to comprehending the interaction between workpieces composed of Cu-Be and diamond tools. AMPCO®, a Cu-Be alloy, plays a crucial role in moulding inserts, offering high wear resistance and contributing to extended mould longevity and improved productivity. The main objective of this work is to assess, identify, and quantify tool wear (TW) mechanisms evaluation while machining AMPCO® with WC-Co uncoated tools and TiAlTaN-coated tools by physical vapour deposition (PVD). Evaluating tool performance while varying cutting length (Lcut) and feed rate (f) at three distinct levels and analysing the surface roughness (SR) produced in the machined surface were the primary purposes of this work. The results obtained with coated tools were distinct from those obtained with uncoated tools. While uncoated tools suffered from substrate abrasion and adhesion, the coated tools suffered mainly from delamination, followed by chipping. Furthermore, f and Lcut significantly influence the quality of the machined surface. TiAlTaN-coated tools performed significantly worse than uncoated tools, proving that the coating needs significant improvements to be considered as an alternative in milling Cu-Be alloys.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: Metal and Thin Film Mechanics · Advanced machining processes and optimization · Advanced materials and composites
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
Affiliations
ISEP, Polytechnic of Porto, Rua Dr. António Bernardino de Almeida, 4249-015 Porto, Portugal
LAETA-INEGI, Associate Laboratory for Energy, Transports and Aerospace, Rua Dr. Roberto Frias 400, 4200-465 Porto, Portugal
Technological College of São José dos Campos, Centro Paula Souza, Avenida Cesare Mansueto Giulio Lattes, 1350 Distrito Eugênio de Melo, São José dos Campos 12247-014, Brazil
Funding
DRIVOLUTION—Transition to the factory of the future · European Structural and Investments Funds
References (64)
Show source-provided references
1. Validation of an extended objective function for the thermal optimisation of injection moulds10.1016/j.ijheatmasstransfer.2022.123365 ↗
2. Nordberg, G.F., Fowler, B.A., and Nordberg, M. (2015). Handbook on the Toxicology of Metals, Academic Press. [4th ed.].10.1016/B978-0-444-59453-2.00001-9 ↗
3. Chakraborty, T. (2024). Encyclopedia of Condensed Matter Physics, Academic Press. [2nd ed.].
4. ASM International (1994). Surface Engineering, ASM International.
5. Nordberg, G.F., Fowler, B.A., and Nordberg, M. (2015). Handbook on the Toxicology of Metals, Academic Press. [4th ed.].10.1016/B978-0-444-59453-2.00001-9 ↗
6. Research on micro-EDM with an auxiliary electrode to suppress stray-current corrosion on C17200 beryllium copper alloy in deionized water10.1007/s00170-017-0478-8 ↗
7. Built-up-edge effects on surface deterioration in micromilling processes10.1016/j.jmapro.2016.03.016 ↗
8. Sousa, V.F.C., Castanheira, J., Silva, F.J.G., Fecheira, J.S., Pinto, G., and Baptista, A. (2021). Wear Behavior of Uncoated and Coated Tools in Milling Operations of AMPCO (Cu-Be) Alloy. Appl. Sci., 11.10.3390/app11167762 ↗
9. Wear behaviour of novel copper alloy as an alternative to copper-beryllium10.1016/j.wear.2023.204817 ↗
10. Huzaim, N.H.M., Rahim, S.Z.A., Musa, L., Abdellah, A.E.-h., Abdullah, M.M.A.B., Rennie, A., Rahman, R., Garus, S., Błoch, K., and Sandu, A.V. (2022). Potential of Rapid Tooling in Rapid Heat Cycle Molding: A Review. Materials, 15.10.3390/ma15103725 ↗
11. Friction and Wear Behavior of C17200 Copper-Beryllium Alloy in Dry and Wet Environments10.1007/s11665-021-05969-w ↗
12. (2015). Standard Specification for Copper-Beryllium Alloy Plate, Sheet, Strip, and Rolled Bar (Standard No. ASTM B 194—15).
13. Sliding bearings with sintered bronze bush lubricated by contaminated water with solid particles—Theoretical and experimental studies10.1016/j.wear.2023.205070 ↗
14. Electropolishing of two kinds of bronze in a deep eutectic solvent (Ethaline)10.1016/j.surfcoat.2020.126060 ↗
15. (2012). Standard Specification for Aluminum Bronze Rod, Bar, and Shapes (Standard No. ASTM B 150/B 150M—12).
16. (2014). Standard Specification for Copper Alloy Sand Castings for General Applications (Standard No. ASTM B 584—14).
17. Kunčická, L., Jambor, M., Weiser, A., and Dvořák, J. (2021). Structural Factors Inducing Cracking of Brass Fittings. Materials, 14.10.3390/ma14123255 ↗
18. (2010). Standard Specification for Free-Cutting Brass Rod, Bar and Shapes for Use in Screw Machines (Standard No. ASTM B 16/B 16M—10).
19. (2017). Standard Specification for Copper and Copper Alloy Forging Rod, Bar, and Shapes (Standard No. ASTM B 124/B 124M—17).
20. Evaluation of newly synthesized multifunctional nanocomposite coated cupronickel alloy in marine environment10.1016/j.matchemphys.2021.124721 ↗
21. (2016). Standard Specification for Copper and Copper-Alloy Seamless Condenser Tubes and Ferrule Stock (Standard No. ASTM B 111/B 111M—16).
22. Nogueira, F.R., Pedroso, A.F.V., Sousa, V.F.C., Sebbe, N.P.V., Sales-Contini, R.C.M., and Barbosa, M.L.S. A Brief Review of Injection-Mould Materials Hybrid Manufacturing Processes. Proceedings of the Flexible Automation and Intelligent Manufacturing: Establishing Bridges for More Sustainable Manufacturing Systems.
23. Friction behaviour evaluation in beryllium–copper threaded connections10.1016/j.ijmecsci.2009.09.004 ↗
24. Modeling and analysis of tool wear mechanisms in diamond turning of copper beryllium alloy10.1016/j.jmapro.2020.04.053 ↗
25. Optimization of Process Parameter Levels During Conventional Milling of Beryllium Copper Alloy Using End Mill
26. Campbell, F.C. (2006). Manufacturing Technology for Aerospace Structural Materials, Elsevier Science.10.1016/B978-185617495-4/50011-1 ↗
27. An investigation of tool and hard particle interaction in nanoscale cutting of copper beryllium10.1016/j.commatsci.2018.01.011 ↗
28. Investigation on adhesive wear process of tool coating surface under high-adhesive rate environment in cutting Beryllium-copper C17200 alloy10.1016/j.matlet.2020.128488 ↗
29. Micro-EDM drilling of high aspect ratio micro-holes and in situ surface improvement in C17200 beryllium copper alloy10.1016/j.jallcom.2017.08.162 ↗
30. The use of copper alloy CuCrZr as a structural material for actively cooled plasma facing and in vessel components10.1016/j.fusengdes.2005.06.056 ↗
31. High Temperature Fatigue Tests of Cu-be and 40CrMoV13.9 Alloys10.1016/j.mspro.2014.06.007 ↗
32. Heat Treating of Nonferrous Alloys10.1007/s13632-013-0074-8 ↗
33. Extending the Lifetime of Copper-beryllium Alloys as Plastic Injection High-end Needle Valve Mold Nozzle Tips Through a Heat-treatment-based Microstructure Optimization Approach10.1007/s11595-023-2743-z ↗
34. Lai, F., Mao, K., Cao, C., Hu, A., Tu, J., and Lin, Y. (2023). Rotating Bending Fatigue Behaviors of C17200 Beryllium Copper Alloy at High Temperatures. Materials, 16.10.3390/ma16020815 ↗
35. Material performance of age-hardened beryllium–copper alloy, CDA-C17200, in a high-pressure, gaseous hydrogen environment10.1016/j.ijhydene.2017.04.270 ↗
36. Sousa, V.F.C., and Silva, F.J.G. (2020). Recent Advances on Coated Milling Tool Technology—A Comprehensive Review. Coatings, 10.10.3390/coatings10030235 ↗
37. Sousa, V.F.C., Da Silva, F.J.G., Pinto, G.F., Baptista, A., and Alexandre, R. (2021). Characteristics and Wear Mechanisms of TiAlN-Based Coatings for Machining Applications: A Comprehensive Review. Metals, 11.10.3390/met11020260 ↗
38. (1982). Basic Quantities in Cutting and Grinding—Part 1: Geometry of the Active Part of Cutting Tools—General Terms, Reference Systems, Tool and Working Angles, Chip Breakers (Standard No. ISO 3002-1:1982(E)).
39. Advances in micro cutting tool design and fabrication10.1088/2631-7990/ab3e7f ↗
40. (2021). Geometrical Product Specifications (GPS)—Surface Texture: Profile—Part 2: Terms, Definitions and Surface Texture Parameters (Standard No. ISO 21920-2:2021(E)).
41. The effects of cut-off length on surface roughness parameters and their correlation with transition friction10.1016/j.ssci.2004.01.002 ↗
42. Echlin, P. (2009). Handbook of Sample Preparation for Scanning Electron Microscopy and X-ray Microanalysis, Springer.10.1007/978-0-387-85731-2 ↗
43. Echlin, P. (2009). Handbook of Sample Preparation for Scanning Electron Microscopy and X-ray Microanalysis, Springer.10.1007/978-0-387-85731-2 ↗
44. (2021). Coated Abrasives—Determination and Designation of Grain Size Distribution—Part 2: Macrogrit Sizes P12 to P220 (Standard No. ISO 6344-2:2021(E)).
45. (2021). Coated Abrasives—Determination and Designation of Grain Size Distribution—Part 3: Microgrit Sizes P240 to P5000 (Standard No. ISO 6344-3:2021(E)).
46. Echlin, P. (2009). Handbook of Sample Preparation for Scanning Electron Microscopy and X-ray Microanalysis, Springer.10.1007/978-0-387-85731-2 ↗
47. Echlin, P. (2009). Handbook of Sample Preparation for Scanning Electron Microscopy and X-ray Microanalysis, Springer.10.1007/978-0-387-85731-2 ↗
48. Argon-to-hydrogen ratio in plasma jet diamond chemical vapour deposition10.1016/j.surfcoat.2004.04.072 ↗
49. Significance of residual stress in PVD-coated carbide cutting tools10.1016/j.cirp.2013.03.101 ↗
50. Pedroso, A.F.V., Sousa, V.F.C., Sebbe, N.P.V., Silva, F.J.G., Campilho, R.D.S.G., Sales-Contini, R.C.M., and Jesus, A.M.P. (2023). A Comprehensive Review on the Conventional and Non-Conventional Machining and Tool-Wear Mechanisms of INCONEL®. Metals, 13.10.3390/met13030585 ↗
51. (1989). Tool Life Testing in Milling—Part 2: End Milling (Standard No. ISO 8688-2:1989(E)).
52. Precision grinding and facing of copper-beryllium alloys10.1016/S0141-6359(99)00024-0 ↗
53. Silva, F.J.G., Martinho, R.P., Martins, C., Lopes, H., and Gouveia, R.M. (2019). Machining GX2CrNiMoN26-7-4 DSS Alloy: Wear Analysis of TiAlN and TiCN/Al2O3/TiN Coated Carbide Tools Behavior in Rough End Milling Operations. Coatings, 9.10.3390/coatings9060392 ↗
54. Study of the wear behaviour of TiAlSiN and TiAlN PVD coated tools on milling operations of pre-hardened tool steel10.1016/j.wear.2021.203695 ↗
55. Cutting forces and wear analysis of Si3N4 diamond coated tools in high speed machining10.1016/j.vacuum.2008.03.065 ↗
56. Surface topography in ball-end milling processes as a function of feed per tooth and radial depth of cut10.1016/j.ijmachtools.2011.10.006 ↗
57. A study on roughness of the micro-end-milled surface produced by a miniatured machine tool10.1016/j.jmatprotec.2005.02.141 ↗
58. Grzesik, W. (2017). Advanced Machining Processes of Metallic Materials, Elsevier. [2nd ed.].10.1016/B978-0-444-63711-6.00015-6 ↗
59. High-speed Machining of Inconel 718 with Ceramic Tools10.1016/S0007-8506(07)62402-0 ↗
60. Rahman, M.A., Bhuiyan, M.S., Sharma, S., Kamal, M.S., Imtiaz, M.M.M., Alfaify, A., Nguyen, T.-T., Khanna, N., Sharma, S., and Gupta, M.K. (2021). Influence of Feed Rate Response (FRR) on Chip Formation in Micro and Macro Machining of Al Alloy. Metals, 11.10.3390/met11010159 ↗
61. Studies on wear behavior of AlTiN-coated WC tool and machined surface quality in micro endmilling of Inconel 71810.1007/s00170-020-05875-w ↗
62. Coated Tools for Metal Cutting—Features and Applications10.1016/S0007-8506(07)63231-4 ↗
63. Reactive HiPIMS deposition of Ti-Al-N: Influence of the deposition parameters on the cubic to hexagonal phase transition10.1016/j.surfcoat.2019.125007 ↗
64. Baptista, A., Silva, F., Porteiro, J., Míguez, J., and Pinto, G. (2018). Sputtering Physical Vapour Deposition (PVD) Coatings: A Critical Review on Process Improvement and Market Trend Demands. Coatings, 8.10.3390/coatings8110402 ↗