Performance studies of multilayer hard surface coatings (TiN/TiCN/Al2O3/TiN) of indexable carbide inserts in hard machining: Part-I (An experimental approach)

Abstract In recent years, hard machining using CBN and ceramic inserts became an emerging technology than traditional grinding and widely used manufacturing processes. However the relatively high cost factors associated with such tools has left a space to look for relatively low cost cutting tool materials to perform in an acceptable range. Multilayer coated carbide insert is the proposed alternative in the present study due to its low cost. Thus, an attempt has been made to have an extensive study on the machinability aspects such as flank wear, chip morphology, surface roughness in finish hard turning of AISI 4340 steel (HRC 47 ± 1) using multilayer coated carbide (TiN/TiCN/Al 2 O 3 /TiN) insert under dry environment. Parametric influences on turning forces are also analyzed. From the machinability study, abrasion and chipping are found to be the dominant wear mechanism in hard turning. Multilayer TiN coated carbide inserts produced better surface quality and within recommendable range of 1.6 μm i.e. comparable with cylindrical grinding. At extreme parametric conditions, the growth of tool wear was observed to be rapid thus surface quality affected adversely. The chip morphology study reveals a more favorable machining environment in dry machining using TiN coated carbide inserts. The cutting speed and feed are found to have the significant effect on the tool wear and surface roughness from ANOVA study. It is evident that, thrust force (Fy) is the largest component followed by tangential force (Fz) and the feed force (Fx) in finish hard turning. The observations yield the machining ability of multilayer TiN coated carbide inserts in hard turning of AISI 4340 steel even at higher cutting speeds.

[1]  J. Paulo Davim,et al.  Modelling of surface finish and tool flank wear in turning of AISI D2 steel with ceramic wiper inserts , 2007 .

[2]  A. Akbari,et al.  Experimental Investigation on the Effect of Workpiece Hardness and Cutting Speed on Surface Roughness in Hard Turning With CBN Tools , 2009, WCE 2009.

[3]  Tuğrul Özel,et al.  Predictive modeling of surface roughness and tool wear in hard turning using regression and neural networks , 2005 .

[4]  Y. Sahin,et al.  Comparison of tool life between ceramic and cubic boron nitride (CBN) cutting tools when machining hardened steels , 2009 .

[5]  E.-G. Ng,et al.  EVALUATION OF CUTTING FORCE AND TEMPERATURE WHEN TURNING HARDENED DIE STEEL WITH AMBORITE AMB90 AND DBC50 TOOLING , 1999 .

[6]  Wuyi Chen,et al.  Cutting forces and surface finish when machining medium hardness steel using CBN tools , 2000 .

[7]  A. Noorul Haq,et al.  Analysis of tool wear and surface finish in hard turning , 2006 .

[8]  Y. K. Chou,et al.  CBN tool wear in hard turning: a survey on research progresses , 2007 .

[9]  Jean-François Rigal,et al.  The effects of cutting conditions on mixed ceramic and cubic boron nitride tool wear and on surface roughness during machining of X200Cr12 steel (60 HRC) , 2005 .

[10]  A. Molinari,et al.  High speed turning for hard material with PCBN inserts: tool wear analysis , 2008 .

[11]  Mohd Yusof Noordin,et al.  The effect of multiple pass cutting on surface integrity when hard turning of AISI D2 cold work tool steel , 2007 .

[12]  Safian Sharif,et al.  Dry turning of tempered martensitic stainless tool steel using coated cermet and coated carbide tools , 2007 .

[13]  Ramón Quiza,et al.  Comparing statistical models and artificial neural networks on predicting the tool wear in hard machining D2 AISI steel , 2008 .

[14]  Ajay P. Malshe,et al.  Tool wear and machining performance of cBN–TiN coated carbide inserts and PCBN compact inserts in turning AISI 4340 hardened steel , 2006 .

[15]  Hossam A. Kishawy,et al.  Effects of process parameters on material side flow during hard turning , 1999 .

[16]  N. R. Dhar,et al.  The effects of cryogenic cooling on chips and cutting forces in turning AISI 1040 and AISI 4320 steels , 2002 .

[17]  D. I. Lalwani,et al.  Experimental investigations of cutting parameters influence on cutting forces and surface roughness in finish hard turning of MDN250 steel , 2008 .

[18]  Zone-Ching Lin,et al.  A study of cutting with a CBN tool , 1995 .

[19]  P. V. Rao,et al.  A surface roughness prediction model for hard turning process , 2007 .

[20]  M. Cakir,et al.  Mathematical modeling of surface roughness for evaluating the effects of cutting parameters and coating material , 2009 .

[21]  J. Paulo Davim,et al.  Comparative evaluation of conventional and wiper ceramic tools on cutting forces, surface roughness, and tool wear in hard turning AISI D2 steel , 2007 .

[22]  Jun Wang.  The effect of the multi-layer surface coating of carbide inserts on the cutting forces in turning operations , 2000 .

[23]  Ali Riza Motorcu,et al.  Surface roughness model in machining hardened steel with cubic boron nitride cutting tool , 2008 .

[24]  Wit Grzesik,et al.  Wear phenomenon in the hard steel machining using ceramic tools , 2008 .

[25]  J. Paulo Davim,et al.  Machinability investigations in hard turning of AISI D2 cold work tool steel with conventional and wiper ceramic inserts , 2009 .

[26]  R. Komanduri,et al.  Machining of Hard Materials , 1984 .

[27]  Young-Woo Park,et al.  Tool Material Dependence of Hard Turning on The Surface Quality , 2002 .

[28]  M. Yallese,et al.  Hard machining of hardened bearing steel using cubic boron nitride tool , 2009 .

[29]  J. Ferreira,et al.  A multivariate hybrid approach applied to AISI 52100 hardened steel turning optimization , 2007 .

[30]  C. K. Toh,et al.  Static and dynamic cutting force analysis when high speed rough milling hardened steel , 2004 .