Micro-grinding has been widely used in aerospace and other industry.However,the small diameter of the micro-grinding tool has limited its machining performance and efficiency.In order to solve the above problems,micro...Micro-grinding has been widely used in aerospace and other industry.However,the small diameter of the micro-grinding tool has limited its machining performance and efficiency.In order to solve the above problems,micro-structure has been applied on the micro-grinding tool.A morphology modeling has been established in this study to characterize the surface of microstructured micro-grinding tool,and the grinding performance of micro-structured micro-grinding tool has been analyzed through undeformed chip thickness,abrasive edge width,and effective distance between abrasives.Then deviation analysis,path optimization and parameter optimization of microchannel array precision grinding have been finished to improve processing quality and efficiency,and the deflection angle has the most obvious effects on the rectangular slot depth,micro-structured micro-grinding tool could reduce 10%surface roughness and 20%grinding force compared to original micro-grinding tool.Finally,the microchannel array has been machined with a size deviation of 2μm and surface roughness of 0.2μm.展开更多
Through systematically theoretical analysis and experimental research,the failure mechanism,of CVD(chemical vapor deposition) coated carbide tools in wear and fracture conditions was studied.On the basis of mechanism ...Through systematically theoretical analysis and experimental research,the failure mechanism,of CVD(chemical vapor deposition) coated carbide tools in wear and fracture conditions was studied.On the basis of mechanism analysis,the specific suitability of the coated tools for cutting conditions was revealed and clarified.展开更多
The characteristics of CrN coated martensitic H13 grade tool steels were studied. CrN coatings were depos- ited by the arc physical vapor deposition （PVD） before and after the pulse plasma nitriding of the samples. ...The characteristics of CrN coated martensitic H13 grade tool steels were studied. CrN coatings were depos- ited by the arc physical vapor deposition （PVD） before and after the pulse plasma nitriding of the samples. The PVD and plasma nitriding techniques were applied in relevant workshops by following the commercial practice parameters. Experimental results showed that CrN coating deposited on the nitrided surfaces exhibited superior scratch and wear resistances as compared to that deposited on the original martensitic surface.展开更多
Lower surface roughness and sharper cutting edge are beneficial for improving the machining quality of the cut?ting tool, while coatings often deteriorate them. Focusing on the diamond coated WC?Co milling cutter, the...Lower surface roughness and sharper cutting edge are beneficial for improving the machining quality of the cut?ting tool, while coatings often deteriorate them. Focusing on the diamond coated WC?Co milling cutter, the abrasive flow machining(AFM) is selected for reducing the surface roughness and sharpening the cutting edge. Comparative cutting tests are conducted on di erent types of coated cutters before and after AFM, as well as uncoated WC?Co one, demonstrating that the boron?doped microcrystalline and undoped fine?grained composite diamond coated cutter after the AFM(AFM?BDM?UFGCD) is a good choice for the finish milling of the 6063 Al alloy in the present case, because it shows favorable machining quality close to the uncoated one, but much prolonged tool lifetime. Besides, compared with the micro?sized diamond films, it is much more convenient and e cient to finish the BDM?UFGCD coated cutter covered by nano?sized diamond grains, and resharpen its cutting edge by the AFM, owing to the lower initial surface roughness and hardness. Moreover, the boron incorporation and micro?sized grains in the underly?ing layer can enhance the film?substrate adhesion, avoid the rapid film removal in the machining process, and thus maximize the tool life(1040 m, four times more than the uncoated one). In general, the AFM is firstly proposed and discussed for post?processing the diamond coated complicated cutting tools, which is proved to be feasible for improving the cutting performance展开更多
Owing to the popularization of coating technology, physical Vapor Deposition (PVD) coated tools have become indispensable in the cutting process. Additionally, the post-treatment of coated tools applied to industrial ...Owing to the popularization of coating technology, physical Vapor Deposition (PVD) coated tools have become indispensable in the cutting process. Additionally, the post-treatment of coated tools applied to industrial production can efectively enhance the surface quality of coating. To improve the processing performance of coated tools, micro abrasive slurry jet (MASJ) polishing technology is frst applied to the post-treatment of coated tools. Subsequently, the efects of process parameters on the surface quality and cutting thickness of coating are investigated via single-factor experiments. In the experiment, the best surface roughness is obtained by setting the working pressure to 0.4 MPa, particle size to 3 μm, incidence angle to 30°, and abrasive mass concentration to 100 g/L. Based on the results of the single-factor experiments, combination experiments are designed, and three types of coated tools with diferent surface qualities and coating thicknesses are obtained. The MASJ process for the post-treatment of coated tools is investigated based on a tool wear experiment and the efects of cutting parameters on the cutting force and workpiece surface quality of three types of cutting tools. The result indicates that MASJ machining can efectively improve the machining performance of coated tools.展开更多
X32CrMoV33 hot work tool steel samples coated with AlTiN and AlTiON were submitted to thermal cycling under conditions that approximate thixoforming of steels and to sliding wear tests at 750 ℃,measured to be the cav...X32CrMoV33 hot work tool steel samples coated with AlTiN and AlTiON were submitted to thermal cycling under conditions that approximate thixoforming of steels and to sliding wear tests at 750 ℃,measured to be the cavity surface temperature shortly after the steel slurry is forced into the thixoforming die.AlTiN and AlTiON coatings provide adequate protection against oxidation of the tool steel substrate,but fail to avoid thermal fatigue cracking.This is attributed to the extensive softening of the substrate,the thermal expansion mismatch between the hot work tool steel and the coatings and residual compressive stresses inherited from the deposition process.The impact of AlTiN and AlTiON coatings on the high temperature wear resistance,on the other hand,is favourable.The improved wear resistance is attributed to the stable,protective surface oxide films.展开更多
The coating material of a tool directly affects the efficiency and cost of machining malleable cast iron.However,the machining adaptability of various coating materials to malleable cast iron has been insufficiently r...The coating material of a tool directly affects the efficiency and cost of machining malleable cast iron.However,the machining adaptability of various coating materials to malleable cast iron has been insufficiently researched.In this paper,turning tests were conducted on cemented carbide tools with different coatings(a thick TiN/TiAlN coating,a thin TiN/TiAlN coating,and a nanocomposite(nc)TiAlSiN coating).All coatings were applied by physical vapor deposition.In a comparative study of chip morphology,cutting force,cutting temperature,specific cutting energy,tool wear,and surface roughness,this study analyzed the cutting characteristics of the tools coated with various materials,and established the relationship between the cutting parameters and machining objectives.The results showed that in malleable cast iron machining,the coating material significantly affects the cutting performance of the tool.Among the three tools,the nc-TiAlSiN-coated carbide tool achieved the minimum cutting force,the lowest cutting temperature,least tool wear,longest tool life,and best surface quality.Moreover,in comparisons between cemented-carbide and compacted-graphite cast iron machined under the same conditions,the wear mechanism of the coated tools was found to depend on the cast iron being machined.Therefore,the performance requirements of a tool depend on multiple factors,and selecting an appropriately coated tool for a particular cast iron material is essential.展开更多
The present work aims at the microstructural characterization of TiAlZrN/ Al2O3 and TiAlZrN/Si3N4 coatings deposited via lateral rotating cathodes. The coatings were deposited using Lateral Rotating Cathodes (LARC) te...The present work aims at the microstructural characterization of TiAlZrN/ Al2O3 and TiAlZrN/Si3N4 coatings deposited via lateral rotating cathodes. The coatings were deposited using Lateral Rotating Cathodes (LARC) technology. The deposited coatings were studied for its cross sectional morphology using scanning electron microscopy. Energy Dispersive Spectrometry was also conducted along the cross section to determine the elemental composition. Micro Vickers hardness test was conducted to determine the hardness of the coatings. The scanning electron microscope images showed that TiAlZrN/Al2O3 coatings showed preferred columnar grain orientation with multilayered structure while TiAlZrN/Si3N4 coatings exhibit a dense grain structure. The TiAlZrN/Si3N4 coating shows a hardness of 31.58 GPa while TiAlZrN/Al2O3 coating shows a hardness of 25.40 GPa. Dry turning tests were performed on AISI 304 stainless steel. The TiAlZrN/Si3N4 coatings show reduced flank wear. Both the coatings even under severe cutting conditions impart surface roughness of less than 1.5 μm.展开更多
A surface engineering approach for a novel pre-treatment of hard metal tool substrate for optimum adhesion of diamond coatings is presented. Firsfly, an alkaline solution was used to etch the WC grains to generate a r...A surface engineering approach for a novel pre-treatment of hard metal tool substrate for optimum adhesion of diamond coatings is presented. Firsfly, an alkaline solution was used to etch the WC grains to generate a rough surface for better mechanical interlocking. Subsequently, surface Co was removed by etching in acid solution. Then the hard metal substrate was boronized to form a compound interlayer which acted as an efficient diffusion barrier to prevent the outward diffusion of Co. Novel nano-microcrystalline composite diamond film coatings with a very smooth surface was deposited on the surface engineering pre-treated hard metal surface. Promising results of measurement in adhesion strength as well as field cutting tests have been obtained.展开更多
Monolayer and bilayer coatings of TiAlN, AlCrN, and AlCrN/TiAlN were deposited onto tungsten carbide inserts using the plasma enhanced physical vapor deposition process. The microstructures of the coatings were charac...Monolayer and bilayer coatings of TiAlN, AlCrN, and AlCrN/TiAlN were deposited onto tungsten carbide inserts using the plasma enhanced physical vapor deposition process. The microstructures of the coatings were characterized using scanning electron microscopy （SEM） and atomic force microscopy （AFM）. The SEM micrographs revealed that the AlrN and AlCrN/TiAlN coatings were uniform and highly dense and contained only a limited number of microvoids. The TiAIN coating was non-uniform and highly porous and contained more micro droplets. The hardness and scratch resistance of the specimens were measured using a nanoindentation tester and scratch tester, respectively. Different phases formed in the coatings were analyzed by X-ray diffraction （XRD）. The AlCrN/TiAlN coating exhibited a higher hardness （32.75 GPa）, a higher Young＇s modulus （561.97 GPa）, and superior scratch resistance （LcN = 46 N） compared to conventional coatings such as TiAlN, A1CrN, and TiN.展开更多
Thixoforging of steels is a potential forming technology,which aims at producing near-net-shaped components with good quality from high strength steels in one forging step.The thixoforging process parameters such as b...Thixoforging of steels is a potential forming technology,which aims at producing near-net-shaped components with good quality from high strength steels in one forging step.The thixoforging process parameters such as billet temperature,temperature distribution after reheating,argon gas pressure,transportation time and forging load were investigated on the thixoforging of non axis-symmetric parts of steel grade X210CrW12.The experimental and numerical study of the material flow and tool temperature load reveal the areas of intensive tool wear,thus being useful for further tool design.Hardened hot working steel X38CrMoV5-1 as a tool bulk material with protecting thin films of TiAlN/γ-Al2O3 shows good experimental results at 170 forging cycles.展开更多
MoS2 metal composite coatings have been successful used in dry turning, but its suitability for dry drilling has not been yet established. Therefore, it is necessary to study the friction and wear behaviors of MoS2/Zr...MoS2 metal composite coatings have been successful used in dry turning, but its suitability for dry drilling has not been yet established. Therefore, it is necessary to study the friction and wear behaviors of MoS2/Zr coated HSS in sliding wear and in drilling processes. In the present study, MoS2/Zr composite coatings are deposited on the surface of W6Mo5Cr4V2 high speed steel（HSS）. Microstructural and fundamental properties of these coatings are examined. Ball-on-disc sliding wear tests on the coated discs are carried out, and the drilling performance of the coated drills is tested. Test results show that the MoS2/Zr composite coatings exhibit decreases friction coefficient to that of the uncoated HSS in sliding wear tests. Energy dispersive X-ray（EDX） analysis on the wear surface indicates that there is a transfer layer formed on the counterpart ball during sliding wear processes, which contributes to the decreasing of the friction coefficient between the sliding couple. Drilling tests indicate that the MoS2/Zr coated drills show better cutting performance compared to the uncoated HSS drills, coating delamination and abrasive are found to be the main flank and rake wear mode of the coated drills. The proposed research founds the base of the application of MoS2 metal composite coatings on dry drilling.展开更多
High speed machining (HSM) technology is one of important aspects of advanced manufacturing technology. Nickel-based superalloys have been widely used in the aircraft and nuclear industry due to their exceptional ther...High speed machining (HSM) technology is one of important aspects of advanced manufacturing technology. Nickel-based superalloys have been widely used in the aircraft and nuclear industry due to their exceptional thermal resistance and the ability to retain mechanical properties at elevated temperatures of service environment over 700 ℃. However, they are classified as difficult-to-cut materials due to their high shear strength, work hardening tendency, highly abrasive carbide particles in the microstructure, strong tendency to weld and form built-up edge and low thermal conductivity. They have a tendency to maintain their strength at high temperature that is generated during machining. The Inconel 718 workpiece material used in the experiment was in the hot forged and annealed condition. The commercially available inserts (all inserts were made by Kennametal Inc.) were selected for the tests, a PVD TiAlN coated carbide, a CVD/PVD TiN/TiCN/TiN coated carbide and a CVD Al 2O 3/TiC/TiCN coated carbide were used at the cutting speed range about 50～100 m/min. Three kinds Sialon grade inserts with various geometry and cutting angles were used at the cutting speed range from 100 m/min to 300 m/min. For evaluating the inserts machinability when high speed cutting Inconel 718, Taylor Formula within certain cutting speeds, an high speed cutting experiment of tool life was carried out to establish the models of tool life by means of rapid facing turning test. The conclusions drawn from the turning of Inconel 718 with silicon nitride based ceramic; PVD and CVD coated carbide inserts are as follows: Studies on tool wear in high speed machining. The thorough investigations and studies were made on the tool wear form, wear process and wear mechanism in high speed cutting of difficult-to-machine materials with ceramic tools and with coated carbides. The major wear mechanisms of nickel-based alloys are interactions of abrasive wear, adhesion wear, micro-breakout and chipping. Optimization analysis on the application of high speed machining. Based on the experimental results, the optimal cutting parameters were determined for machining of Inconel 718 at high speed. The recommendation of tool inserts for high speed cutting inconel 718 were ceramic inserts of KY2000 with negative rake angle and KY2100 with round type, the PVD coated carbide insert KC7310 was recommended for its lower price.展开更多
The deposition mechanism of diamond film on cutting tools and the state of the interface between film and substrate are studied theoretically and experimentally. Methods for controlling diamond crystalline state and i...The deposition mechanism of diamond film on cutting tools and the state of the interface between film and substrate are studied theoretically and experimentally. Methods for controlling diamond crystalline state and improving adhesion of diamond films to substrates are proposed to improve the quality of diamond-coated tools. Experiments are performed by cutting Al-Si18% alloy and SiCp/Al composite with diamond coated tool. The results indicate that the life of coated tools is 90 times higher than that of non-coated tools. Wear mechanism of diamond-coated tools is also studied.展开更多
The FEM model of TiBN and TiBN/TiN coated cutting tool in milling of H13 steel w as developed. Process variables such as temperature and stress in the coating l ayer as well as in the substrate were analyzed. The eff...The FEM model of TiBN and TiBN/TiN coated cutting tool in milling of H13 steel w as developed. Process variables such as temperature and stress in the coating l ayer as well as in the substrate were analyzed. The efficacy of the present FEM analysis was verified by conducting controlled milling experiments on AISI H13 t o collect the relevant tool life and force data.The results show that the stress in a coated tool can significantly be reduced compared to an uncoated cutting t ool,possibly due to surface coatings improving the tribological properties of cu tting tools.Coatings with good thermal properties also help to improve the therm al behavior of cutting tool.展开更多
Chemical vapor deposition (CVD) diamond coated drills are fabricated by depositing diamond films on Co-cemented tungsten carbide (WC-Co) drills. The characteristics of as-deposited diamond coatings are investigated by...Chemical vapor deposition (CVD) diamond coated drills are fabricated by depositing diamond films on Co-cemented tungsten carbide (WC-Co) drills. The characteristics of as-deposited diamond coatings are investigated by scanning electron microscope (SEM) and Raman spectra. To evaluate the cutting performance of diamond coated drills, comparative drilling tests are conducted using diamond coated and uncoated WC-Co drills, with carbon fiber reinforced plastics (CFRPs) as the workpiece on a high-speed computer numerical control (CNC) machine. Thrust force and tool wear are measured during the drilling process. The results show that diamond coated drill exhibits better cutting performance, compared with the uncoated drill. The value of flank wear is about 70 μm after machining 90 holes, about a half of that of the WC-Co drill with 145 μm after drilling only 30 holes. The wear rate of WC-Co drill is higher than that of diamond coated drill before diamond films peeling off. The diamond coated drill achieves more predictable hole quality. The improved cutting performance of the diamond coated drill is due to the high hardness, wear resistance and low coefficient of friction.展开更多
A series of metal cutting experiments was performed on a CNC lathe to evaluate the performance of various coatings on different tool substrates. The workpiece material was plain medium carbon steel and the cutting too...A series of metal cutting experiments was performed on a CNC lathe to evaluate the performance of various coatings on different tool substrates. The workpiece material was plain medium carbon steel and the cutting tool materials were carbide and cermet inserts coated with various single as well as multilayer coatings. Machining was done under various cutting conditions of speed and feed-rate, and for various durations of Cutting. The output parameters studied were the cutting forces (axial, radial and tangential), the surface roughness of the workpiece, as well as the tool wear (crater and flank wear). From these results, the performances of the various cutting inserts are evaluated and compared. Results show that cutting forces are significantly lower when using coated cermets than when using coated carbides although different coatings on the same substrate also result in different cutting forces. However, there is less difference in the surface roughness of the finished workpiece for the various coatings and substrates.展开更多
Hard coatings are used to improve the wear resistance of metals which largely depends on adhesion between substrate and coating.The wear and friction behavior of uncoated and TiCN-coated D2,M2 and M4 steels were evalu...Hard coatings are used to improve the wear resistance of metals which largely depends on adhesion between substrate and coating.The wear and friction behavior of uncoated and TiCN-coated D2,M2 and M4 steels were evaluated by apin-on-disk test under lubricated conditions.In order to evaluate the influence of lubricant on wear performance,dry friction tests were also performed.The results showed that friction coefficients were very similar for both uncoated and TiCN-coated steels.Under lubricated conditions,the uncoated D2 tool steel exhibited the lowest friction coefficient,but the TiCN-coated D2 steel presented the smallest wear rate.Abrasion was the main wear mechanism in all the tribocouples.Additionally,microhardness measurements were carried out,finding an influence of the steel substrate on the hardness of the coatings.Besides,adhesion test was conducted,suggesting agood adhesion of class 1 between substrates and TiCN coatings.展开更多
基金co-supported by the Enterprise Innovation and Development Joint Program of the National Natural Science Foundation of China(No.U20B2032)Open Project Funding of State Key Laboratory for High Performance Tools(GXNGJSKL-2024-08)+1 种基金Open Foundation of the State Key Laboratory of Intelligent Manufacturing Equipment and Technology(IMETKF2023005)Introduced Innovative Scientific Research Team Project of Zhongshan(the tenth batch)(CXTD2023008)。
文摘Micro-grinding has been widely used in aerospace and other industry.However,the small diameter of the micro-grinding tool has limited its machining performance and efficiency.In order to solve the above problems,micro-structure has been applied on the micro-grinding tool.A morphology modeling has been established in this study to characterize the surface of microstructured micro-grinding tool,and the grinding performance of micro-structured micro-grinding tool has been analyzed through undeformed chip thickness,abrasive edge width,and effective distance between abrasives.Then deviation analysis,path optimization and parameter optimization of microchannel array precision grinding have been finished to improve processing quality and efficiency,and the deflection angle has the most obvious effects on the rectangular slot depth,micro-structured micro-grinding tool could reduce 10%surface roughness and 20%grinding force compared to original micro-grinding tool.Finally,the microchannel array has been machined with a size deviation of 2μm and surface roughness of 0.2μm.
文摘Through systematically theoretical analysis and experimental research,the failure mechanism,of CVD(chemical vapor deposition) coated carbide tools in wear and fracture conditions was studied.On the basis of mechanism analysis,the specific suitability of the coated tools for cutting conditions was revealed and clarified.
文摘The characteristics of CrN coated martensitic H13 grade tool steels were studied. CrN coatings were depos- ited by the arc physical vapor deposition （PVD） before and after the pulse plasma nitriding of the samples. The PVD and plasma nitriding techniques were applied in relevant workshops by following the commercial practice parameters. Experimental results showed that CrN coating deposited on the nitrided surfaces exhibited superior scratch and wear resistances as compared to that deposited on the original martensitic surface.
基金Supported by National Natural Science Foundation of China(Grant No.51275302)China Postdoctoral Science Foundation Special Funded Project(Grant No.2016T90370)China Postdoctoral Science Foundation(Grant No.2015M580327)
文摘Lower surface roughness and sharper cutting edge are beneficial for improving the machining quality of the cut?ting tool, while coatings often deteriorate them. Focusing on the diamond coated WC?Co milling cutter, the abrasive flow machining(AFM) is selected for reducing the surface roughness and sharpening the cutting edge. Comparative cutting tests are conducted on di erent types of coated cutters before and after AFM, as well as uncoated WC?Co one, demonstrating that the boron?doped microcrystalline and undoped fine?grained composite diamond coated cutter after the AFM(AFM?BDM?UFGCD) is a good choice for the finish milling of the 6063 Al alloy in the present case, because it shows favorable machining quality close to the uncoated one, but much prolonged tool lifetime. Besides, compared with the micro?sized diamond films, it is much more convenient and e cient to finish the BDM?UFGCD coated cutter covered by nano?sized diamond grains, and resharpen its cutting edge by the AFM, owing to the lower initial surface roughness and hardness. Moreover, the boron incorporation and micro?sized grains in the underly?ing layer can enhance the film?substrate adhesion, avoid the rapid film removal in the machining process, and thus maximize the tool life(1040 m, four times more than the uncoated one). In general, the AFM is firstly proposed and discussed for post?processing the diamond coated complicated cutting tools, which is proved to be feasible for improving the cutting performance
基金Supported by National Natural Science Foundation of China(Grant No.51735003)Research Start-up Fee for Doctoral Personnel of Binzhou University of China(Grant No.2019Y12)Key Program of NSFC-Guangdong Joint Fund of China(Grant No.U1201245).
文摘Owing to the popularization of coating technology, physical Vapor Deposition (PVD) coated tools have become indispensable in the cutting process. Additionally, the post-treatment of coated tools applied to industrial production can efectively enhance the surface quality of coating. To improve the processing performance of coated tools, micro abrasive slurry jet (MASJ) polishing technology is frst applied to the post-treatment of coated tools. Subsequently, the efects of process parameters on the surface quality and cutting thickness of coating are investigated via single-factor experiments. In the experiment, the best surface roughness is obtained by setting the working pressure to 0.4 MPa, particle size to 3 μm, incidence angle to 30°, and abrasive mass concentration to 100 g/L. Based on the results of the single-factor experiments, combination experiments are designed, and three types of coated tools with diferent surface qualities and coating thicknesses are obtained. The MASJ process for the post-treatment of coated tools is investigated based on a tool wear experiment and the efects of cutting parameters on the cutting force and workpiece surface quality of three types of cutting tools. The result indicates that MASJ machining can efectively improve the machining performance of coated tools.
文摘X32CrMoV33 hot work tool steel samples coated with AlTiN and AlTiON were submitted to thermal cycling under conditions that approximate thixoforming of steels and to sliding wear tests at 750 ℃,measured to be the cavity surface temperature shortly after the steel slurry is forced into the thixoforming die.AlTiN and AlTiON coatings provide adequate protection against oxidation of the tool steel substrate,but fail to avoid thermal fatigue cracking.This is attributed to the extensive softening of the substrate,the thermal expansion mismatch between the hot work tool steel and the coatings and residual compressive stresses inherited from the deposition process.The impact of AlTiN and AlTiON coatings on the high temperature wear resistance,on the other hand,is favourable.The improved wear resistance is attributed to the stable,protective surface oxide films.
基金Supported by National Major Science and Technology Projects of China(Grant No.SK201901A31-04)Key Program of NSFC-Guangdong Joint Fund,China(Grant No.U1201245).
文摘The coating material of a tool directly affects the efficiency and cost of machining malleable cast iron.However,the machining adaptability of various coating materials to malleable cast iron has been insufficiently researched.In this paper,turning tests were conducted on cemented carbide tools with different coatings(a thick TiN/TiAlN coating,a thin TiN/TiAlN coating,and a nanocomposite(nc)TiAlSiN coating).All coatings were applied by physical vapor deposition.In a comparative study of chip morphology,cutting force,cutting temperature,specific cutting energy,tool wear,and surface roughness,this study analyzed the cutting characteristics of the tools coated with various materials,and established the relationship between the cutting parameters and machining objectives.The results showed that in malleable cast iron machining,the coating material significantly affects the cutting performance of the tool.Among the three tools,the nc-TiAlSiN-coated carbide tool achieved the minimum cutting force,the lowest cutting temperature,least tool wear,longest tool life,and best surface quality.Moreover,in comparisons between cemented-carbide and compacted-graphite cast iron machined under the same conditions,the wear mechanism of the coated tools was found to depend on the cast iron being machined.Therefore,the performance requirements of a tool depend on multiple factors,and selecting an appropriately coated tool for a particular cast iron material is essential.
文摘The present work aims at the microstructural characterization of TiAlZrN/ Al2O3 and TiAlZrN/Si3N4 coatings deposited via lateral rotating cathodes. The coatings were deposited using Lateral Rotating Cathodes (LARC) technology. The deposited coatings were studied for its cross sectional morphology using scanning electron microscopy. Energy Dispersive Spectrometry was also conducted along the cross section to determine the elemental composition. Micro Vickers hardness test was conducted to determine the hardness of the coatings. The scanning electron microscope images showed that TiAlZrN/Al2O3 coatings showed preferred columnar grain orientation with multilayered structure while TiAlZrN/Si3N4 coatings exhibit a dense grain structure. The TiAlZrN/Si3N4 coating shows a hardness of 31.58 GPa while TiAlZrN/Al2O3 coating shows a hardness of 25.40 GPa. Dry turning tests were performed on AISI 304 stainless steel. The TiAlZrN/Si3N4 coatings show reduced flank wear. Both the coatings even under severe cutting conditions impart surface roughness of less than 1.5 μm.
文摘A surface engineering approach for a novel pre-treatment of hard metal tool substrate for optimum adhesion of diamond coatings is presented. Firsfly, an alkaline solution was used to etch the WC grains to generate a rough surface for better mechanical interlocking. Subsequently, surface Co was removed by etching in acid solution. Then the hard metal substrate was boronized to form a compound interlayer which acted as an efficient diffusion barrier to prevent the outward diffusion of Co. Novel nano-microcrystalline composite diamond film coatings with a very smooth surface was deposited on the surface engineering pre-treated hard metal surface. Promising results of measurement in adhesion strength as well as field cutting tests have been obtained.
文摘Monolayer and bilayer coatings of TiAlN, AlCrN, and AlCrN/TiAlN were deposited onto tungsten carbide inserts using the plasma enhanced physical vapor deposition process. The microstructures of the coatings were characterized using scanning electron microscopy （SEM） and atomic force microscopy （AFM）. The SEM micrographs revealed that the AlrN and AlCrN/TiAlN coatings were uniform and highly dense and contained only a limited number of microvoids. The TiAIN coating was non-uniform and highly porous and contained more micro droplets. The hardness and scratch resistance of the specimens were measured using a nanoindentation tester and scratch tester, respectively. Different phases formed in the coatings were analyzed by X-ray diffraction （XRD）. The AlCrN/TiAlN coating exhibited a higher hardness （32.75 GPa）, a higher Young＇s modulus （561.97 GPa）, and superior scratch resistance （LcN = 46 N） compared to conventional coatings such as TiAlN, A1CrN, and TiN.
基金the German Research Foundation for the financial support within the project T01 of the TFB 289 ‘Forming of metals in the semi-solid state and their properties’
文摘Thixoforging of steels is a potential forming technology,which aims at producing near-net-shaped components with good quality from high strength steels in one forging step.The thixoforging process parameters such as billet temperature,temperature distribution after reheating,argon gas pressure,transportation time and forging load were investigated on the thixoforging of non axis-symmetric parts of steel grade X210CrW12.The experimental and numerical study of the material flow and tool temperature load reveal the areas of intensive tool wear,thus being useful for further tool design.Hardened hot working steel X38CrMoV5-1 as a tool bulk material with protecting thin films of TiAlN/γ-Al2O3 shows good experimental results at 170 forging cycles.
基金supported by National Natural Science Foundation of China(Grant No. 51075237)Shandong Provincial Taishan Scholar Program of China+1 种基金Shandong Provincial Outstanding Young Scholar Science Foundation of China(Grant No. JQ200917)Research Fundfor the Doctoral Program of Higher Education of China(Grant No20110131130002)
文摘MoS2 metal composite coatings have been successful used in dry turning, but its suitability for dry drilling has not been yet established. Therefore, it is necessary to study the friction and wear behaviors of MoS2/Zr coated HSS in sliding wear and in drilling processes. In the present study, MoS2/Zr composite coatings are deposited on the surface of W6Mo5Cr4V2 high speed steel（HSS）. Microstructural and fundamental properties of these coatings are examined. Ball-on-disc sliding wear tests on the coated discs are carried out, and the drilling performance of the coated drills is tested. Test results show that the MoS2/Zr composite coatings exhibit decreases friction coefficient to that of the uncoated HSS in sliding wear tests. Energy dispersive X-ray（EDX） analysis on the wear surface indicates that there is a transfer layer formed on the counterpart ball during sliding wear processes, which contributes to the decreasing of the friction coefficient between the sliding couple. Drilling tests indicate that the MoS2/Zr coated drills show better cutting performance compared to the uncoated HSS drills, coating delamination and abrasive are found to be the main flank and rake wear mode of the coated drills. The proposed research founds the base of the application of MoS2 metal composite coatings on dry drilling.
文摘High speed machining (HSM) technology is one of important aspects of advanced manufacturing technology. Nickel-based superalloys have been widely used in the aircraft and nuclear industry due to their exceptional thermal resistance and the ability to retain mechanical properties at elevated temperatures of service environment over 700 ℃. However, they are classified as difficult-to-cut materials due to their high shear strength, work hardening tendency, highly abrasive carbide particles in the microstructure, strong tendency to weld and form built-up edge and low thermal conductivity. They have a tendency to maintain their strength at high temperature that is generated during machining. The Inconel 718 workpiece material used in the experiment was in the hot forged and annealed condition. The commercially available inserts (all inserts were made by Kennametal Inc.) were selected for the tests, a PVD TiAlN coated carbide, a CVD/PVD TiN/TiCN/TiN coated carbide and a CVD Al 2O 3/TiC/TiCN coated carbide were used at the cutting speed range about 50～100 m/min. Three kinds Sialon grade inserts with various geometry and cutting angles were used at the cutting speed range from 100 m/min to 300 m/min. For evaluating the inserts machinability when high speed cutting Inconel 718, Taylor Formula within certain cutting speeds, an high speed cutting experiment of tool life was carried out to establish the models of tool life by means of rapid facing turning test. The conclusions drawn from the turning of Inconel 718 with silicon nitride based ceramic; PVD and CVD coated carbide inserts are as follows: Studies on tool wear in high speed machining. The thorough investigations and studies were made on the tool wear form, wear process and wear mechanism in high speed cutting of difficult-to-machine materials with ceramic tools and with coated carbides. The major wear mechanisms of nickel-based alloys are interactions of abrasive wear, adhesion wear, micro-breakout and chipping. Optimization analysis on the application of high speed machining. Based on the experimental results, the optimal cutting parameters were determined for machining of Inconel 718 at high speed. The recommendation of tool inserts for high speed cutting inconel 718 were ceramic inserts of KY2000 with negative rake angle and KY2100 with round type, the PVD coated carbide insert KC7310 was recommended for its lower price.
文摘The deposition mechanism of diamond film on cutting tools and the state of the interface between film and substrate are studied theoretically and experimentally. Methods for controlling diamond crystalline state and improving adhesion of diamond films to substrates are proposed to improve the quality of diamond-coated tools. Experiments are performed by cutting Al-Si18% alloy and SiCp/Al composite with diamond coated tool. The results indicate that the life of coated tools is 90 times higher than that of non-coated tools. Wear mechanism of diamond-coated tools is also studied.
基金Funded by the National Natural Science Foundation of China (No.50465003) the Natural Science Foundation of Jiangxi Province (No.0350005) the State Key Laboratory Foundation of Die Technology at Huazhong University of Science and Technology (No.04 8)
文摘The FEM model of TiBN and TiBN/TiN coated cutting tool in milling of H13 steel w as developed. Process variables such as temperature and stress in the coating l ayer as well as in the substrate were analyzed. The efficacy of the present FEM analysis was verified by conducting controlled milling experiments on AISI H13 t o collect the relevant tool life and force data.The results show that the stress in a coated tool can significantly be reduced compared to an uncoated cutting t ool,possibly due to surface coatings improving the tribological properties of cu tting tools.Coatings with good thermal properties also help to improve the therm al behavior of cutting tool.
基金the National Natural Science Foundation of China(Nos.51275302 and 51005154)the Important National Science and Technology Specific Projects(No.2012ZX04003-031)
文摘Chemical vapor deposition (CVD) diamond coated drills are fabricated by depositing diamond films on Co-cemented tungsten carbide (WC-Co) drills. The characteristics of as-deposited diamond coatings are investigated by scanning electron microscope (SEM) and Raman spectra. To evaluate the cutting performance of diamond coated drills, comparative drilling tests are conducted using diamond coated and uncoated WC-Co drills, with carbon fiber reinforced plastics (CFRPs) as the workpiece on a high-speed computer numerical control (CNC) machine. Thrust force and tool wear are measured during the drilling process. The results show that diamond coated drill exhibits better cutting performance, compared with the uncoated drill. The value of flank wear is about 70 μm after machining 90 holes, about a half of that of the WC-Co drill with 145 μm after drilling only 30 holes. The wear rate of WC-Co drill is higher than that of diamond coated drill before diamond films peeling off. The diamond coated drill achieves more predictable hole quality. The improved cutting performance of the diamond coated drill is due to the high hardness, wear resistance and low coefficient of friction.
文摘A series of metal cutting experiments was performed on a CNC lathe to evaluate the performance of various coatings on different tool substrates. The workpiece material was plain medium carbon steel and the cutting tool materials were carbide and cermet inserts coated with various single as well as multilayer coatings. Machining was done under various cutting conditions of speed and feed-rate, and for various durations of Cutting. The output parameters studied were the cutting forces (axial, radial and tangential), the surface roughness of the workpiece, as well as the tool wear (crater and flank wear). From these results, the performances of the various cutting inserts are evaluated and compared. Results show that cutting forces are significantly lower when using coated cermets than when using coated carbides although different coatings on the same substrate also result in different cutting forces. However, there is less difference in the surface roughness of the finished workpiece for the various coatings and substrates.
基金support of Tecnológico Nacional de México(TNM)(Grant No.5724.16P)
文摘Hard coatings are used to improve the wear resistance of metals which largely depends on adhesion between substrate and coating.The wear and friction behavior of uncoated and TiCN-coated D2,M2 and M4 steels were evaluated by apin-on-disk test under lubricated conditions.In order to evaluate the influence of lubricant on wear performance,dry friction tests were also performed.The results showed that friction coefficients were very similar for both uncoated and TiCN-coated steels.Under lubricated conditions,the uncoated D2 tool steel exhibited the lowest friction coefficient,but the TiCN-coated D2 steel presented the smallest wear rate.Abrasion was the main wear mechanism in all the tribocouples.Additionally,microhardness measurements were carried out,finding an influence of the steel substrate on the hardness of the coatings.Besides,adhesion test was conducted,suggesting agood adhesion of class 1 between substrates and TiCN coatings.
