Cubic Boron Nitride (cBN) based nanocomposite coatings on cutting inserts with chip breakers for hard turning applications

Abstract Deposition of cBN (5∼20 μm) is of great technological importance but poses significant difficulty in terms of depositing it from vapor phase(s). Initial proof-of-concept work has indicated that a thick cBN–TiN composite coating can be deposited in a practical hybrid deposition process using electrostatic spray coating (ESC) and chemical vapor infiltration (CVI), and that coated inserts can provide significant improvement in machining performance. In this paper, the development of a nanocomposite cBN–TiN coating especially for hard turning is presented. Aspects of the coating on chip-breaker inserts, repeatability, and process optimization for the given application are discussed. Characterization of the coating shows a repeatable uniform deposition. Encouraging tool life and workpiece surface roughness have been achieved in machining of AISI 4340 hardened steels (50∼53 HRC) using the coated inserts.

[1]  Mats Andersson,et al.  Effect of chamfer angle on wear of PCBN cutting tool , 2003 .

[2]  A. Matthews,et al.  Handbook of Hard Coatings: Edited by Rointan E Bunshah; Noyes Publications/William Andrew Publishing, New York 2001 (Available from American Technical Publishers Ltd, 27-29 Knowl Piece, Wilbury Way, Hitchin, Herts, SG4 0SX, England, Price £94) , 2001 .

[3]  A. Malshe,et al.  CBN-TiN Composite Coating Using a Novel Combinatorial Method—Structure and Performance in Metal Cutting , 2003 .

[4]  S. Matsumoto,et al.  Synthesis of thick and high quality cubic boron nitride films by r.f. bias assisted d.c. jet plasma chemical vapor deposition , 2004 .

[5]  Taylor,et al.  Growth and characterization of epitaxial cubic boron nitride films on silicon. , 1991, Physical review. B, Condensed matter.

[6]  D. Bhat,et al.  Review of CVD TiN coatings for wear-resistant applications: deposition processes, properties and performance* , 1994 .

[7]  A. Moisan,et al.  Surface integrity in finish hard turning of case-hardened steels , 2003 .

[8]  S. Barringer,et al.  Physical Properties Important to Electrostatic and Non electrostatic Powder Transfer Efficiency in a Tumble Drum , 2003 .

[9]  L. Schäfer,et al.  Diamond coatings and cBN coatings for tools , 1998 .

[10]  Henry Shaw,et al.  Gas–solid fluidization in a centrifugal field , 2001 .

[11]  Chun Liu,et al.  Single-step superfinish hard machining: Feasibility and feasible cutting conditions , 1996 .

[12]  T. Ikeda.  Cubic boron nitride films synthesized by low‐energy ion‐beam‐enhanced vapor deposition , 1992 .

[13]  A. Pal,et al.  Synthesis of cubic boron nitride film by inductively coupled plasma CVD technique , 2004 .

[14]  G. Ottaviani,et al.  Science and technology of thin films , 1995 .

[15]  John Farrell Hughes,et al.  Electrostatic Powder Coating , 1984 .

[16]  Gerry Byrne,et al.  Cutting tool wear in the machining of hardened steels , 2001 .

[17]  Masao Murakawa,et al.  The synthesis of cubic BN films using a hot cathode plasma discharge in a parallel magnetic field , 1990 .

[18]  P. Tessier,et al.  Deposition of boron nitride films by PVD methods: transition from h-BN to c-BN , 2004 .

[19]  O. Tsuda,et al.  PREPARATION OF CUBIC BORON NITRIDE FILMS BY RADIO FREQUENCY BIAS SPUTTERING , 1992 .

[20]  János Kundrák,et al.  On the Dry Machining of Steel Surfaces Using Superhard Tools , 2002 .

[21]  Synthesis and characterization of cubic boron nitride films — investigations of growth and annealing processes , 2002 .

[22]  Shui-Tong Lee,et al.  Thick and adherent cubic boron nitride films grown on diamond interlayers by fluorine-assisted chemical vapor deposition , 2004 .