Hostname: page-component-8448b6f56d-xtgtn Total loading time: 0 Render date: 2024-04-23T13:57:29.241Z Has data issue: false hasContentIssue false
  • English
  • Français

Wear mechanism of coated and uncoated carbide cutting tool in machining process

Published online by Cambridge University Press:  28 December 2015

Jaharah A. Ghani ,
Che Hassan Che Haron ,
Mohd Shahir Kasim ,
Mohd Amri Sulaiman  and
Siti Haryani Tomadi
Jaharah A. Ghani*
Affiliation:
Department of Mechanical and Material Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, 43600 Bangi, Selangor, Malaysia
Che Hassan Che Haron
Affiliation:
Department of Mechanical and Material Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, 43600 Bangi, Selangor, Malaysia
Mohd Shahir Kasim
Affiliation:
Department of Process, Faculty of Manufacturing Engineering, Universiti Teknikal Malaysia Melaka, 49100 Hang Tuah Jaya, Melaka, Malaysia
Mohd Amri Sulaiman
Affiliation:
Department of Process, Faculty of Manufacturing Engineering, Universiti Teknikal Malaysia Melaka, 49100 Hang Tuah Jaya, Melaka, Malaysia
Siti Haryani Tomadi
Affiliation:
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 26300 Kuantan, Pahang, Malaysia
*
a)Address all correspondence to this author. e-mail: jaharahaghani@ukm.edu.my
Get access

Abstract

A carbide cutting tool is widely used in machining process due to its availability and being cheaper than a better performance cutting tool, such as cubic boron nitride. The carbide cutting tool also has substantial hardness and toughness that is suitable to be applied in intermittent cutting. This paper presents the case study of a wear mechanism experienced on the cutting edge of the coated and uncoated carbide tools in turning and milling processes. The wear mechanisms of carbide cutting tools were investigated in machining Inconel 718, titanium alloy Ti–6Al–4V extra-low interstitial, and aluminum metal matrix composite (AlSi/AlN MMC) at their high cutting speed regime. The tools failed primarily due to wear on the flank and rake faces. The failure mode of the carbide cutting tools was similar regardless of the machining operations and coating is believed to enhance the tool life, but once removed, the tool fails similar to that with the uncoated tool.

Keywords

wear mechanismcarbide cutting toolmilling processturning processInconel 718Ti–6Al–4V ELIAlSi/AlN MMC
Type
Invited Articles
Information
Journal of Materials Research , Volume 31 , Issue 13: Focus Issue: Advances and Challenges in Carbon-based Tribomaterials , 14 July 2016 , pp. 1873 - 1879
Copyright
Copyright © Materials Research Society 2015 

Access options

Get access to the full version of this content by using one of the access options below. (Log in options will check for institutional or personal access. Content may require purchase if you do not have access.)

References

REFERENCES

Hutchings, I.M.: Abrasive and erosive wear tests for thin coatings: A unified approach. Tribol. Int. 31, 5–15 (1998).Google Scholar
Wang, Z. and Zhou, Q.: Applying a population growth model to simulate wear of rough surfaces during running-in. Wear 294–295, 356–363 (2012).Google Scholar
Liao, Y.S., Lin, H.M., and Wang, J.H.: Behaviors of end milling Inconel 718 superalloy by cemented carbide tools. J. Mater. Process. Technol. 201, 460–465 (2008).Google Scholar
Sharman, A.R.C., Hughes, J.I., and Ridgway, K.: Workpiece surface integrity and tool life issues when turning inconel 718™ nickel based superalloy. Mach. Sci. Technol. 8, 399–414 (2004).Google Scholar
Srinivasulu, K. and Subhash, B.K.: Studies On The Residual Stresses Due To Machining On Super Alloy Inconel-718. In International Conference on Aerospace Science and Technology, Bangalore, India, 2008.Google Scholar
Alauddin, M., El Baradie, M.A., and Hashmi, M.S.J.: Optimization of surface finish in end milling Inconel 718. J. Mater. Process. Technol. 56, 54–65 (1996).Google Scholar
Bradley, E.: Superalloys. In ASM International, Metal Park, 1988.Google Scholar
Krain, H.R., Sharman, A.R.C., and Ridgway, K.: Optimisation of tool life and productivity when end milling Inconel 718TM. J. Mater. Process. Technol. 189, 153–161 (2007).CrossRefGoogle Scholar
Sharman, A., Dewes, R.C., and Aspinwall, D.K.: Tool life when high speed ball nose end milling Inconel 718. J. Mater. Process. Technol. 118, 29–35 (2001).CrossRefGoogle Scholar
Che-Haron, C.H. and Jawaid, A.: The effect of machining on surface integrity of titanium alloy Ti-6% Al-4% V. J. Mater. Process. Technol. 166, 188–192 (2005).Google Scholar
Wang, Z.M. and Ezugwu, E.O.: Performance of PVD-coated carbide tools when machining Ti-6Al-4V©. Tribol. Trans. 40, 81–86 (1997).Google Scholar
Jawaid, A., Sharif, S., and Koksal, S.: Evaluation of wear mechanisms of coated carbide tools when face milling titanium alloy. J. Mater. Process. Technol. 99, 266–274 (2000).Google Scholar
Muthukrishnan, N., Murugan, M., and Rao, K.P.: An investigation on the machinability of Al-SiC metal matrix composites using pcd inserts. Int. J. Adv. Manuf. Technol. 38, 447–454 (2008).Google Scholar
Vaziri, R., Delfosse, D., Pageau, G., and Poursartip, A.: High-speed impact response of particulate metal matrix composite materials—An experimental and theoretical investigation. Int. J. Impact Eng. 13, 329–352 (1993).Google Scholar
Barnes, S., Pashby, I.R., and Mok, D.K.: The effect of workpiece temperature on the machinability of an aluminum/SiC MMC. J. Manuf. Sci. Eng., Trans. ASME 118, 422–427 (1996).Google Scholar
Heath, P.J.: Developments in applications of PCD tooling. J. Mater. Process. Technol. 116, 31–38 (2001).Google Scholar
Hung, N.P., Yeo, S.H., and Oon, B.E.: Effect of cutting fluid on the machinability of metal matrix composites. J. Mater. Process. Technol. 67, 157–161 (1997).Google Scholar
Yang, Y., Boom, R., Irion, B., van Heerden, D-J., Kuiper, P., and de Wit, H.: Recycling of composite materials. Chem. Eng. Process.: Process Intensif. 51, 53–68 (2012).CrossRefGoogle Scholar
Ding, X., Liew, W.Y.H., and Liu, X.D.: Evaluation of machining performance of MMC with PCBN and PCD tools. Wear 259, 1225–1234 (2005).CrossRefGoogle Scholar
Looney, L.A., Monaghan, J.M., O'Reilly, P., and Taplin, D.M.R.: The turning of an Al/SiC metal-matrix composite. J. Mater. Process. Technol. 33, 453–468 (1992).CrossRefGoogle Scholar
Hung, N.P., Boey, F.Y.C., Khor, K.A., Oh, C.A., and Lee, H.F.: Machinability of cast and powder-formed aluminum alloys reinforced with SiC particles. J. Mater. Process. Technol. 48, 291–297 (1995).Google Scholar
Durante, S., Rutelli, G., and Rabezzana, F.: Aluminum-based MMC machining with diamond-coated cutting tools. Surf. Coat. Technol. 94–95, 632–640 (1997).Google Scholar
Kasim, M.S., Che Haron, C.H., Ghani, J.A., Sulaiman, M.A., and Yazid, M.Z.A.: Wear mechanism and notch wear location prediction model in ball nose end milling of Inconel 718. Wear 302, 1171–1179 (2013).Google Scholar
Jawaid, A., Koksal, S., and Sharif, S.: Cutting performance and wear characteristics of PVD coated and uncoated carbide tools in face milling Inconel 718 aerospace alloy. J. Mater. Process. Technol. 116, 2–9 (2001).Google Scholar
El-Gallab, M. and Sklad, M.: Machining of Al/SiC particulate metal matrix composites: Part II: Workpiece surface integrity. J. Mater. Process. Technol. 83, 277–285 (1998).Google Scholar
Andrewes, C.J.E., Feng, H-Y., and Lau, W.M.: Machining of an aluminum/SiC composite using diamond inserts. J. Mater. Process. Technol. 102, 25–29 (2000).CrossRefGoogle Scholar
Sulaiman, M.A., Che Haron, C.H., Ghani, J.A., and Kasim, M.S.: The study of wear process on uncoated carbide cutting tool in machining titanium alloy. J. Appl. Sci. Res. 8, 4821–4827 (2012).Google Scholar
Arsecularatne, J.A., Zhang, L.C., and Montross, C.: Wear and tool life of tungsten carbide, PCBN and PCD cutting tools. Int. J. Mach. Tools Manuf. 46, 482–491 (2006).Google Scholar