Mechanical and tribological properties of PVD-coated cemented carbide as evaluated by a new multi-pass scratch testing method

A new test method based on multipass scratch testing has been developed for evaluating the mechanical and tribological properties of thin, hard coatings. The proposed test method uses a pin-on-disc tribometer and during testing a Rockwell C diamond stylus is used as the “pin” and loaded against the rotating coated sample. The influence of normal load on the number of cycles to coating damage is investigated and the resulting coating damage mechanisms are evaluated by posttest scanning electron microscopy. The present study presents the test method by evaluating the performance of Ti0.86Si0.14N, Ti0.34Al0.66N, and (Al0.7Cr0.3)2O3 coatings deposited by cathodic arc evaporation on cemented carbide inserts. The results show that the test method is quick, simple, and reproducible and can preferably be used to obtain relevant data concerning the fatigue, wear, chipping, and spalling characteristics of different coating-substrate composites. The test method can be used as a virtually nondestructive test and, for example, be used to evaluate the fatigue and wear resistance as well as the cohesive and adhesive interfacial strength of coated cemented carbide inserts prior to cutting tests.

Implications of the reduction of cutting fluid in drilling AISI P20 steel with carbide tools

The machining of hardened steel is becoming increasingly important in manufacturing processes. Machined parts made with hardened steel are often subjected to high service demands, which require great resistance and quality. The machining of this material submits the tools to high mechanical and thermal loads, which increases the tool wear and affects the surface integrity of the part. In that context, this work presents a study of drilling of AISI P20 steel with carbide tools, analyzing the effects on the process caused by the reduction of cutting fluid supply and its relation with the tool wear and the surface integrity of the piece. The major problem observed in the tests was a difficulty for chips to flow through the drill flute, compromising their expulsion from the hole. After a careful analysis, a different machining strategy was adopted to solve the problem

Effect of green machining on distortion and surface finishing in advanced ceramic

An alternative for grinding of sintered ceramic is the machining on the green state of the ceramic, which presents easy cutting without the introduction of harmful defects to its mechanical resistance. However, after sintering there are invariably distortions caused by the heterogeneous distribution of density gradients, which are located in the most outlying portions of the compacted workpiece. In order to minimize these density gradients, this study examined the influence of different allowance values and their corresponding influence in distortion after sintering alumina specimens with 99.8 % purity by turning operation using cemented carbide tool. Besides distortion, other output variables were analyzed, such as tool wear, cutting force and surface roughness of green and sintered ceramics. Results showed a distortion reduction up to 81.4%. Green machining is beneficial for reducing surface roughness in both green and sintered states. Cutting tool wear has a direct influence on surface roughness and cutting force.

Rough turning of titanium alloy (6Al-4V)

Metal machining is the complex process due the used cutting parameters. In metal cutting process, materials of workpiece differ widely in their ability to deform plastically, to fracture and to sustain tensile stresses. Moreover, the material involved in the process has a great influence in these operations. The Ti-6Al-4V alloy is very used in the aeronautical industry, mainly in the manufacture of engines, has very important properties such the mechanical and corrosion resistance in high te mperatures. The turning of the Ti-Al-4V alloy is very difficult due the rapid tool wear. Such behavior result of the its low thermal conductivity in addition the high reactivity with the cutting tool. The formed chip is segmented and regions of the large deformation named shear bands plows formed. The machinability of the cutting process can be evaluated by several measures including power consume, machined surface quality, tool wear, tool life, microstructure and morphology of the obtained chip. This paper studies the effect of cutting parameters, speed and feed rates, in the tool wear and chip properties using uncoating cemented carbide tool. Microe-structural characterization of the chip and tool wear was performed using scanning electron microscopy (SEM) and Light Optical Mcroscopy (LOM).

Fresamento com ar quente: uma proposta para minimizar a formação de trincas térmicas em ferramentas de metal duro

This work presents the results, analyses and conclusions about a study carried out with objective of minimizing the thermal cracks formation on cemented carbide inserts during face milling. The main focus of investigation was based on the observation that milling process is an interrupted machining process, which imposes cyclic thermal loads to the cutting tool, causing frequent stresses changes in its superficial and sub-superficial layers. These characteristics cause the formation of perpendicular cracks from cutting edge which aid the cutting tool wear, reducing its life. Several works on this subject emphasizing the thermal cyclic behavior imposed by the milling process as the main responsible for thermal cracks formation have been published. In these cases, the phenomenon appears as a consequence of the difference in temperature experienced by the cutting tool with each rotation of the cutter, usually defined as the difference between the temperatures in the cutting tool wedge at the end of the cutting and idle periods (T factor). Thus, a technique to minimize this cyclic behavior with objective of transforming the milling in an almost-continuous process in terms of temperature was proposed. In this case, a hot air stream was applied into the idle period, during the machining process. This procedure aimed to minimize the T factor. This technique was applied using three values of temperature from the hot air stream (100, 350 e 580 oC) with no cutting fluid (dry condition) and with cutting fluid mist (wet condition) using the hot air stream at 580oC. Besides, trials at room temperature were carried out. Afterwards the inserts were analyzed using a scanning electron microscope, where the quantity of thermal cracks generated in each condition, the wear and others damages was analyzed. In a general way, it was found that the heating of the idle period was positive for reducing the number of thermal cracks during face milling with cemented carbide inserts. Further, the cutting fluid mist application was effective in reducing the wear of the cutting tools.

Torneamento de liga de níquel Pyromet 31V (N07032) com ferramentas de metal duro

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Efeito da variação da velocidade de corte e de avanço no torneamento de Eucalipto

Due to the rapid development of some species such as pine and eucalyptus and a growing demand for raw materials, timber, there was a need for detailed studies to better use and higher quality in products derived from wood. In order to contribute to to better utilization of wood ,this study aims to analyze the quality of the wood surface after machining Corymbia citrodora around, with varying feed rates (40, 70, 100 mm/mim), shear rate (1.88, 2.19, 2.51 m/s) and with the use of inserts for turning new and used (cemented carbide). 18 were used bodies and each body was made three different assays for each test were a total of 54 tests three replicates. This study will also addres the analysis of power consumption for each of the tests. With the results obtained through experiments, including the surface roughness of parts and power consumption for each test, we try to evaluate the power consumption in machining with the variations in cutting speed and feed, with two tools carbide

Tool wear evaluations in friction stir processing of commercial titanium Ti–6Al–4V

This research addresses the application of friction stir welding (FWS) of titanium alloy Ti–6Al–4V. Friction stir welding is a recent process, developed in the 1990s for aluminum joining; this joining process is being increasingly applied in many industries from basic materials, such as steel alloys, to high performance alloys, such as titanium. It is a process in great development and has its economic advantages when compared to conventional welding. For high performance alloys such as titanium, a major problem to overcome is the construction of tools that can withstand the extreme process environment. In the literature, the possibilities approached are only few tungsten alloys. Early experiments with tools made of cemented carbide (WC) showed optimistic results consistent with the literature. It was initially thought that WC tools may be an option to the FSW process since it is possible to improve the wear resistance of the tool. The metallographic analysis of the welds did not show primary defects of voids (tunneling) or similar internal defects due to processing, only defects related to tool wear which can cause loss of weld quality. The severe tool wear caused loss of surface quality and inclusions of fragments inside the joining, which should be corrected or mitigated by means of coating techniques on tool, or the replacement of cemented carbide with tungsten alloys, as found in the literature.

The study of ternary carbides formation during SPS consolidation process in the WC-Co-steel system

Tungsten carbide has a wide range of applications, mainly cemented carbides made of WC and Co, as wear resistant materials. However, the high cost of WC-Co powders encourages the use of a substrate to manufacture a functionally graded material (FGM) tool made of WC-Co and a tool steel. These materials join the high wear resistance of the cemented carbide and the toughness of the steel. This work deals with the study interaction of the WC-Co and H13 steel to design a functionally graded material by means of spark plasma sintering (SPS). The SPS, a novel sintering technique reaching the consolidation of the powders at relatively low temperatures and short dwell times, is a promising technique in processing materials. In this study, WC, H13 steel, WC-Co, WC-H13 steel and WC-Co-H13 steel bulk samples were investigated using scanning electron microscopy and X-ray diffraction techniques to evaluate the phase transformations involved during SPS consolidation process. The W(2)C and W(3)Fe(3)C precipitation were identified after the SPS consolidation of the WC and WC-H13 steel samples, respectively. The precipitation Of W(4)Co(2)C was also identified in the WC-Co and WC-Co-H13 steel samples. The WC-H 13 steel and WC-Co-H13 steel were also evaluated after heat treatments at 1100 degrees C for 9 h, which enhanced the chemical interaction and the precipitation of W(3)Fe(3)C and W(4)Co(2)C, respectively. (C) 2009 Elsevier Ltd. All rights reserved.

Surface integrity analysis in the super duplex stainless steel ASTM-A890 after machining

The purpose of this paper was to study the main effects of the turning in the superficial integrity of the duplex stainless steel ASTM A890-6A. The tests were conducted on a turning centre with carbide tools and the main entrances variables were: tool material class, feed rate, cutting depth, cutting speed and cutting fluid utilisation. The answers were analysed: microstructural analysis by optical microscopy and x-ray diffraction, cutting forces measurements by a piezoelectric dynamometer, surface roughness, residual stress by x-ray diffraction technique and the microhardness measurements. The results do not show any changes in the microstructural of the material, even when the greater cutting parameters were used. The smaller feed rate (0.1 mm/v), smaller cutting speed (110 m/min) and the greater cutting depth (0.5 mm) provided the smaller values for the tensile residual stress, the smaller surface roughness and the greater microhardness.

Keraamisten teräpalojen käyttö niukkaseosteisten terästen lastuamiseen normaaleissa toimitustiloissa

Tämän tutkimuksen tavoitteena oli tutkia keraamisten kääntöterien soveltuvuus niukkaseosteräksille ja M-käsittelyn vaikutus teränkestoaikoihin. Lisäksi tavoitteena oli tutkia keraamiseosten erityisominaisuudet ja muodostaa käsitys keraamisilla kääntöterillä sorvaamisen erityisvaatimuksista. Kirjallisuusosassa selvitettiin tutkimushetkellä saatavissa olleet keraamiset teräaineseokset ja niiden ominaisuudet sekä selvitettiin keraamisten kääntöterien viimeaikaiset kehitystrendit. Lastuamistutkimus toteutettiin standardin ISO 3685:1993 mukaisesti, minkä lisäksi mitattiin lastuamisvoimat ja tehtiin kokeessa käytetyille terille lastunmurtokoe. Koemateriaalit olivat Imatra Steelin GreenCut, Hydax 25, M-käsittelemätön 42CrMo4 ja M-käsitelty MoC410M. Kokeissa käytetyt kääntöterät olivat eri valmistajien alumiinioksiditeriä, titaanikarbidiseostettuja alumiinioksiditeriä, kuituvahvisteisia ja yksi puhdas titaanikarbidiseosteinen terä. Koetulosten perusteella hyvän teränkestoajan saavuttamiseksi on tärkeää valita oikea keraamiseos ja sille soveltuvat parametrit. Oikein valituilla parametreilla M-terästä sorvattaessa tulokset ylittävät kovametalleilla saavutettavissa olevat arvot. Tulosten perusteella niukkaseostettujen terästen sorvaus onnistuu hyvin keraamisilla kääntöterillä, mutta kovametallisorvaukseen verrattuna syöttöä on laskettava ja lastuamisnopeutta lisättävä. Tämän työn tuloksia voidaan soveltaa sopivissa olosuhteissa toteutettavassa kappaletavaratuotannossa. Sovelluksen onnistuminen vaatii tukevat työstöolosuhteet ja riittävien lastuamisnopeuksien saavuttamisen.

Tribological Testing of Some Potential PVD and CVD Coatings for Steel Wire Drawing Dies

Cemented carbide is today the most frequently used drawing die material in steel wire drawing applications. This is mainly due to the possibility to obtain a broad combination of hardness and toughness thus meeting the requirements concerning strength, crack resistance and wear resistance set by the wire drawing process. However, the increasing cost of cemented carbide in combination with the possibility to increase the wear resistance of steel through the deposition of wear resistant CVD and PVD coatings have enhanced the interest to replace cemented carbide drawing dies with CVD and PVD coated steel wire drawing dies. In the present study, the possibility to replace cemented carbide wire drawing dies with CVD and PVD coated steel drawing dies have been investigated by tribological characterisation, i.e. pin-on-disc and scratch testing, in combination with post-test observations of the tribo surfaces using scanning electron microscopy, energy dispersive X-ray spectroscopy and 3D surface profilometry. Based on the results obtained, CVD and PVD coatings aimed to provide improved tribological performance of steel wire drawing dies should display a smooth surface topography, a high wear resistance, a high fracture toughness (i.e. a high cracking and chipping resistance) and intrinsic low friction properties in contact with the wire material. Also, the steel substrate used must display a sufficient load carrying capacity and resistance to thermal softening. Of the CVD and PVD coatings evaluated in the tribological tests, a CVD TiC and a PVD CrC/C coating displayed the most promising results.

Effects of milling condition on the surface integrity of hot forged steel

This paper presents a study on the influence of milling condition on workpiece surface integrity focusing on hardness and roughness. The experimental work was carried out on a CNC machining center considering roughing and finishing operations. A 25 mm diameter endmill with two cemented carbide inserts coated with TiN layer were used for end milling operation. Low carbon alloyed steel Cr-Mo forged at 1200 degrees C was used as workpiece on the tests. Two kinds of workpiece conditions were considered, i.e. cur cooled after hot forging and normalized at 950 degrees C for 2 h. The results showed that finishing operation was able to significantly decrease the roughness by at least 46% without changing the hardness. on the other hand, roughing operation caused an increase in hardness statistically significant by about 6%. The machined surface presented deformed regions within feed marks, which directly affected the roughness. Surface finish behavior seems to correlate to the chip ratio given the decrease of 25% for roughing condition, which damaged the chip formation. The material removal rate for finishing operation 41% greater than roughing condition demonstrated to be favorable to the heat dissipation and minimized the effect on material hardness.

Análise do processo de torneamento a quente auxiliado por resistência elétrica de quartzo

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