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A novel method of assessing and predicting coated cutting tool wear during Inconel DA 718 turning

Published on Aug 1, 2019in Wear 2.95
· DOI :10.1016/j.wear.2019.202949
S. Capasso (Polytechnic University of Turin), Jose Mario Paiva4
Estimated H-index: 4
(McMaster University)
+ 7 AuthorsStephen C. Veldhuis27
Estimated H-index: 27
(McMaster University)
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Abstract
Abstract This work investigates the wear characteristics of two different coating systems deposited on cemented carbide tools and used in the finish turning of an Inconel DA718 aerospace alloy. The two coatings were: (a) a new nanocomposite multilayer Ti25Al65Cr10 N/Ti20Al52Cr22Si8N PVD coating, and (b) an AlTiN benchmark coating. Four different cutting speeds (60, 80, 100 and 120 m/min) were employed during this study. Wear behavior was characterized using three-dimensional volumetric wear progression, as well as flank wear progression, wear mechanism evaluation, and cutting force analysis. A tool life predictive model was created for this process based on both 3D and flank wear patterns. The tool with the nanocomposite coating outperformed the AlTiN benchmark coating under higher speed conditions, and both tools performed best under a surface speed of 80 m/min. The primary wear mechanisms responsible for the performance of these coatings differ in relation to the adaptive behavior of the nanocomposite coating. In addition, tool wear predictions modeled under different cutting conditions demonstrated an estimated accuracy of 93%.
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  • Citations (0)
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References42
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Published on Jan 1, 2019in Wear 2.95
Ben D. Beake27
Estimated H-index: 27
(Yale University),
Luis Isern1
Estimated H-index: 1
(Cranfield University)
+ 1 AuthorsG.S. Fox-Rabinovich25
Estimated H-index: 25
(McMaster University)
Abstract A novel micro-scale repetitive impact test has been developed to assess the fracture resistance of hard coatings under dynamic high strain rate loading. It is capable of significantly higher impact energies than in the nano-impact test. It retains the intrinsic depth-sensing capability of the nano-impact test enabling the progression of the damage process to be monitored throughout the test, combined with the opportunity to use indenters of less sharp geometry and still cause rapid coat...
Published on Aug 1, 2018in Journal of Manufacturing Processes 3.46
Jong-Tae Baek2
Estimated H-index: 2
,
Wan-Sik Woo6
Estimated H-index: 6
(Changwon National University),
Choon-Man Lee14
Estimated H-index: 14
(Changwon National University)
Abstract Difficult-to-machine materials are being widely used in various industries. However, these materials are much more difficult to machine using conventional machining (CM) methods than other common materials, because of their superior material properties such as high strength, stiffness and brittleness. Thermally assisted machining (TAM) methods have been developed to address this problem. Laser assisted machining (LAM) is a type of TAM process in which a workpiece is locally softened by ...
Published on Feb 1, 2018in Tribology International 3.52
Wit Grzesik18
Estimated H-index: 18
(Opole University of Technology),
P. Nieslony16
Estimated H-index: 16
(Opole University of Technology)
+ 2 AuthorsPiotr Laskowski4
Estimated H-index: 4
(Pratt & Whitney)
Abstract This paper contributes to broadening the knowledge regarding cutting tool wear in the finish turning operations of nickel-chromium-based superalloy Inconel 718. Three cutting tools coated with heat isolating TiAlN/AlTiN layers with different stoichiometry ratios recommended as specially designed cutting tools for aerospace industry applications are tested. The primary comparison of tool wear resistance was based on the wear curves related to the cutting time and the removed material vol...
Published on Jan 18, 2018in THE Coatings 2.33
Kenji Yamamoto9
Estimated H-index: 9
,
Majid Abdoos1
Estimated H-index: 1
+ 5 AuthorsStephen C. Veldhuis27
Estimated H-index: 27
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...
Ben D. Beake27
Estimated H-index: 27
(Yale University),
Jose L. Endrino22
Estimated H-index: 22
(Cranfield University)
+ 2 AuthorsStephen C. Veldhuis27
Estimated H-index: 27
(McMaster University)
Abstract In developing advanced wear-resistant coatings for tribologically extreme highly loaded applications such as high speed metal cutting a critical requirement is to investigate their behaviour at elevated temperature since the cutting process generates frictional heat which can raise the temperature in the cutting zone to 700–900 °C or more. High temperature micro-tribological tests provide severe tests for coatings that can simulate high contact pressure sliding/abrasive contacts at elev...
Jose Mario Paiva4
Estimated H-index: 4
,
Ricardo D. Torres7
Estimated H-index: 7
(PUCPR: Pontifícia Universidade Católica do Paraná)
+ 5 AuthorsG.S. Fox-Rabinovich25
Estimated H-index: 25
(McMaster University)
In this work, machining of the superduplex stainless steel was investigated using cemented carbide turning inserts with chemical vapor deposited (CVD) TiCN + Al2O3 as well as physical vapor deposited (PVD) TiCN and AlTiN coatings. These three coating system were tested during finish turning operation of superduplex stainless steel. It has been found that unfavorable friction and wear conditions were observed when TiCN- and TiCN + Al2O3-coated tools were used. On the other hand, the AlTiN-coated ...
Shang Sui4
Estimated H-index: 4
(NPU: Northwestern Polytechnical University),
Jing Chen16
Estimated H-index: 16
(NPU: Northwestern Polytechnical University)
+ 3 AuthorsWeidong Huang21
Estimated H-index: 21
(NPU: Northwestern Polytechnical University)
Abstract In this paper, a comparative study of high-cycle fatigue tests ( T =650 °C, f =110 Hz, R =0.1, K t =1) were carried out with wrought Inconel 718 and LAMed Inconel 718. The results show that the influences of the Laves phases on high-cycle fatigue properties are based on the applied stress amplitudes. At a low stress amplitude, most of the Laves phases held their original morphologies. The fatigue cracks stopped in front or detoured around them, which means that the unbroken Laves phases...
Published on Mar 1, 2017in Surface & Coatings Technology 3.19
M.S.I. Chowdhury1
Estimated H-index: 1
(McMaster University),
S. Chowdhury1
Estimated H-index: 1
(McMaster University)
+ 8 AuthorsG.S. Fox-Rabinovich25
Estimated H-index: 25
(McMaster University)
Abstract In the machining of Ti alloys, it is challenging to optimise the cutting tool life and process productivity. It is not a trivial task to find an efficient strategy to improve the tool life during machining of Ti alloys using surface engineered tooling. In the case of rough turning operation with strong built up edge formation we establish that it can be achieved through the application of self-lubricating TiB 2 PVD coating. It has been shown that the application of a TiB 2 coating resul...
Published on Aug 9, 2016in Entropy 2.42
G.S. Fox-Rabinovich25
Estimated H-index: 25
,
Jose Mario Paiva4
Estimated H-index: 4
+ 5 AuthorsStephen C. Veldhuis27
Estimated H-index: 27
In this paper, we will develop a strategy for controlling the self-organized critical process using the example of extreme tribological conditions caused by intensive build-up edge (BUE) formation that take place during machining of hard-to-cut austentic superduplex stainless steel SDSS UNS32750. From a tribological viewpoint, machining of this material involves intensive seizure and build-up edge formation at the tool/chip interface, which can result in catastrophic tool failure. Built-up edge ...
Published on May 1, 2016in Surface & Coatings Technology 3.19
Junfeng Yuan3
Estimated H-index: 3
(McMaster University),
Kenji Yamamoto9
Estimated H-index: 9
(Kobe Steel)
+ 5 AuthorsG.S. Fox-Rabinovich25
Estimated H-index: 25
(McMaster University)
Abstract A nano- multilayer TiAlCrSiYN/TiAlCrN was deposited by Physical Vapor Deposition (PVD) on cemented carbide turning inserts. Assessment of the performance of the coated inserts in machining of DA718 Inconel was made at various cutting speeds during the initial, running-in stage of wear. Three types of machining conditions were used: i. Regular cutting speed (40 m/min) used in industrial practice; ii. Higher cutting speed of 60 m/min, and iii. Accelerated (higher speed followed by regular...
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