Investigations on the machinability performance of Al2O3/TiCN CVD coated carbide tools in sustainable high-speed hard-turning of AISI 4340 alloy steel

IF 1.8 4区 材料科学 Q3 MATERIALS SCIENCE, MULTIDISCIPLINARY Materials Research Express Pub Date : 2024-09-15 DOI:10.1088/2053-1591/ad7657
Nabil Jouini, Saima Yaqoob and Jaharah A Ghani
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Abstract

This study investigates the effectiveness of CVD coated carbide inserts in turning hardened AISI 4340 steel at high-machining speed V = 300, 350 m min−1 under sustainable dry cutting environment. Experiments were executed in accordance to Taguchi L4 orthogonal array and crucial machinability aspects tool life, tool wear progression and mechanism, cutting force, and surface roughness were evaluated in detail. The results of this study revealed that Al2O3/TiCN coating successfully inhibited the faster progression of tool wear at low cutting speed (300 m min−1), feed rate (0.05 mm rev−1) and depth of cut (0.1 mm), thus delivering the highest tool life of 19.25 min and lowest cutting force of 76.8 N. However, better surface finish of 0.305 μm was obtained at high cutting speed (350 m min−1), low feed rate (0.05 mm rev−1), and high depth of cut (0.1 mm). Nevertheless, at high cutting speed (350 m min−1) and feed rate (0.1 mm rev−1), involvement of intense thermal-mechanical effects suppressed the effectiveness of coating and tool completed its useful life at 9.24 min. Severe flaking on the cutting edge was observed at high machining parameters. Scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS) analysis revealed that adhesion, oxidation, and small scale chipping and abrasion were the primary wear mechanisms attributing in competing the tool life criteria (Vb = 300 μm) in all cutting conditions. Furthermore, it was established that the cutting force and surface roughness increased with increasing tool flank wear due to coating delamination, material adhesion and tool chipping. This research emphasizes the significant potential of adopting Al2O3/TiCN coated carbide inserts for high-speed industrial hard-turning of AISI 4340 steel.
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Al2O3/TiCN CVD 涂层硬质合金刀具在 AISI 4340 合金钢持续高速硬车削中的加工性能研究
本研究探讨了 CVD 涂层硬质合金刀片在可持续干切削环境下,以 V = 300、350 m min-1 的高速车削淬硬 AISI 4340 钢的有效性。实验按照 Taguchi L4 正交阵列进行,详细评估了刀具寿命、刀具磨损进程和机理、切削力和表面粗糙度等关键加工性能。研究结果表明,在低切削速度(300 m min-1)、低进给量(0.05 mm rev-1)和低切削深度(0.1 mm)条件下,Al2O3/TiCN 涂层成功地抑制了刀具的快速磨损,因此刀具寿命最高,为 19.25 分钟,切削力最低,为 76.8 N。然而,在高切削速度(350 米/分钟-1)和高进给量(0.1 毫米/分钟-1)条件下,强烈的热机械效应抑制了涂层的效果,刀具在 9.24 分钟时结束了使用寿命。在高加工参数下,切削刃上出现了严重的剥落。扫描电子显微镜(SEM)和能量色散光谱(EDS)分析表明,在所有切削条件下,粘附、氧化、小范围崩角和磨损是导致刀具寿命达标(Vb = 300 μm)的主要磨损机制。此外,由于涂层脱层、材料粘附和刀具崩刃,切削力和表面粗糙度随着刀具侧面磨损的增加而增加。这项研究强调了采用 Al2O3/TiCN 涂层硬质合金刀片进行 AISI 4340 钢高速工业硬车削的巨大潜力。
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来源期刊
Materials Research Express
Materials Research Express MATERIALS SCIENCE, MULTIDISCIPLINARY-
CiteScore
4.50
自引率
4.30%
发文量
640
审稿时长
12 weeks
期刊介绍: A broad, rapid peer-review journal publishing new experimental and theoretical research on the design, fabrication, properties and applications of all classes of materials.
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