Hard machining performance of PVD AlCrN coated Al2O3/TiCN ceramic inserts as a function of thin film thickness
Source abstract
Abstract
Abstract In the present work, AlCrN coating was deposited on Al2O3/TiCN ceramic inserts with varying thin film thickness using physical vapor deposition (PVD) technique. The thickness, surface morphology, chemical composition, hardness and adhesion strength of the coating to the substrate were characterized by field-emission scanning electron microscopy (FESEM), scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), micro-indentations and scratch tests respectively. The machining performance of uncoated and coated tools was investigated in hard turning of AISI 52100 steel (62 HRC) under dry environment. The cutting behavior was analyzed in terms of machining forces, tool temperature, wear, friction and chip morphology. Further, a 3D finite element model with hybrid friction criterion has been adopted to support the experimental findings. The results revealed that coating/substrate adhesion and edge radius were the deciding criteria for the machining performance of coated tools with 3 µm coating thickness tool exhibiting best turning performance on Al2O3/TiCN mixed ceramic insert.
Source: openaire · Quality: candidate unverified · Source record ↗
Research context
OpenAlex topics: Metal and Thin Film Mechanics · Advanced machining processes and optimization · Advanced Surface Polishing Techniques
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (39)
Show source-provided references
1. 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 ↗
2. Wear characteristics in turning high hardness alloy steel by ceramic and CBN tools10.1016/S0924-0136(98)00376-8 ↗
3. Cutting temperatures during hard turning – measurements and effects on white layer formation in AISI 5210010.1016/j.jmatprotec.2014.01.016 ↗
4. Performance of mixed ceramics and CBN tools during hard turning of martensitic stainless steel10.1007/s00170-014-6506-z ↗
5. Influence of tribological properties on the performance of uncoated, CVD and PVD coated tools in machining of Incoloy 82510.1016/j.triboint.2016.05.027 ↗
6. Hard turning: AISI 4340 high strength low alloy steel and AISI D2 cold work tool steel10.1016/j.jmatprotec.2005.04.082 ↗
7. Experimental and numerical investigations on the effect of varying AlTiN coating thickness on hard machining performance of Al2O3-TiCN mixed ceramic inserts10.1016/j.surfcoat.2016.11.080 ↗
8. Influence of a micropatterned insert on characteristics of the tool-workpiece interface in a hard turning process10.1016/j.jmatprotec.2015.09.018 ↗
9. Microstructure and mechanical properties of gas pressure sintered Al2O3/ TiCN composite10.1016/j.ceramint.2006.07.001 ↗
10. Experimental investigation into machinability of hardened AISI 4140 steel using TiN coated ceramic tool10.1016/j.measurement.2014.11.008 ↗
11. Gas pressure sintering of AlO/TiCN composite10.1016/j.ceramint.2004.11.007 ↗
12. Ceramics tool materials with alumina matrix
13. Structure and properties of PVD and CVD coated Al2O3 + TiC mixed oxide tool ceramics for dry on high speed cutting processes10.1016/j.jmatprotec.2005.02.089 ↗
14. Mechanisms and characteristics of direct cutting of tungsten carbide using a diamond-coated carbide end mill10.1007/s00170-015-8324-3 ↗
15. Wear mechanisms and tool performance of TiAlN PVD coated inserts during machining of AISI 4140 steel10.1016/j.wear.2006.03.052 ↗
16. High speed cutting of Inconel 718 with coated carbide and ceramic inserts10.1016/S0924-0136(02)00590-3 ↗
17. PVD-CrAlN and TiAlN coated Si3N4 ceramic cutting tools −1. Microstructure, turning performance and wear mechanism
18. Structure and properties of PVD TiAlN and TiAlN/CrAlN coated Ti(C, N)-based cermets10.1016/j.ceramint.2016.10.151 ↗
19. Cutting performance and wear mechanism of Ti-Al-N/Al-Cr-O coated silicon nitride ceramic cutting inserts10.1016/j.ceramint.2014.02.038 ↗
20. Determination of the optimum TiN coating thickness on WC inserts for machining carbon steels10.1016/j.jmatprotec.2004.04.277 ↗
21. Effect of coating thickness on the characteristics and dry machining performance of TiN film deposited on cemented carbide inserts using CFUBMS10.1080/10426914.2010.526978 ↗
22. Investigations on the effects of multi-layered coated inserts in machining Ti-6Al−4V alloy with experiments and finite element simulations10.1016/j.cirp.2010.03.055 ↗
23. Finite-element-analysis of the relationship between chip geometry and stress triaxiality distribution in the chip breakage location of metal cutting operations10.1016/j.simpat.2015.03.009 ↗
24. A simulation approach for estimating flank wear and material removal rate in turning of Inconel 71810.1016/j.simpat.2014.12.004 ↗
25. Finite element modelling of machining of AISI 316 steel: numerical simulation and experimental validation10.1016/j.simpat.2009.10.001 ↗
26. Investigations on the effects of friction modeling in finite element simulation of machining10.1016/j.ijmecsci.2009.10.001 ↗
27. Finite element modeling of hard turning process via a micro-textured tool10.1007/s00170-014-6747-x ↗
28. 3D finite element analysis of tool wear in machining10.1016/j.cirp.2008.03.123 ↗
29. Investigation and FEM-based simulation of tool wear in turning operations with uncoated carbide tools10.1016/j.wear.2010.04.013 ↗
30. Computational modelling of 3D turning: influence of edge micro-geometry on forces, stresses, friction and tool wear in PcBN tooling10.1016/j.jmatprotec.2009.03.002 ↗
31. Oerlikon Balzers, Balinit Alcrona Pro, (n.d.). 〈www.oerlikon.com/balzers〉.
32. The influence of friction models on finite element simulations of machining10.1016/j.ijmachtools.2005.07.001 ↗
33. Hard AlTiN, AlCrN PVD coatings for machining of austenitic stainless steel10.1016/j.surfcoat.2005.10.030 ↗
34. Hardness-based flow stress and fracture models for numerical simulation of hard machining AISI 52100 bearing steel10.1016/j.msea.2004.01.012 ↗
35. Influence of deposition temperature and time during PVD coating of CrN on corrosive wear in liquid aluminium10.1016/S0257-8972(01)01366-4 ↗
36. H. Takikawa, Review of cathodic arc deposition for preparing droplet-free thin films, in: Proceedings of the International Symposium on Discharges and Electrical Insulation in Vacuum, ISDEIV, 2, 2006, pp. 525–530. 〈https://dx.doi.org/10.1109/DEIV.2006.357354〉.10.1109/DEIV.2006.357354 ↗
37. Optimization of the cutting edge geometry of coated carbide tools in dry turning of steels using a finite element analysis10.1080/10910340902776051 ↗
38. Mechanical properties of hardened AISI 52100 steel in hard machining processes10.1115/1.1413775 ↗
39. Thermal properties of cutting tool coatings at high temperatures10.1016/j.tca.2012.03.029 ↗