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Tribological evaluation of TiN and TiAlN coated PM-HSS gear cutter when machining 19MnCr5 steel

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Abstract

Two PVD coated powder metallurgy high speed steel (PM-HSS) gear cutters were investigated when machining helical gears made from AISI 19MnCr5 steel with hardness between 140 and 180 HV. Machining trials were carried out with gear cutters coated with TiAlN (nano layers) and TiN (mono layer). Crater and flank wears were measured and analysed after all the machining trials. Analyses of the worn tools show that the TiAlN coated gear cutter performed better than the TiN coated gear cutter. This can be attributed to its nano layers and the higher hardness of the TiAlN coating. The dominant tool wear mechanisms were adhesion, abrasion, delaminating of the coating layer and chipping of the cutting edge.

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Abbreviations

CVD:

Chemical vapour deposition

CNC:

Computer numerical control

doc:

Depth of cut (mm)

EDX:

Energy dispersive x-ray

f :

Feed rate (mm/rev)

H a :

Hardness of the abrasive grains (kgf/mm2)

H a/H s :

Hardness ratio

H s :

Hardness of the surface (kgf/mm2)

HV:

Vickers hardness (kgf/mm2, where kgf/mm2=9.807 MPa)

PCBN:

Polycrystalline cubic boron nitride

PCD:

Polycrystalline compact diamond

PM-HSS:

Powder metallurgy – high speed steel

PVD:

Physical vapour deposition

SEM:

Scanning electron microscope

VB max :

Maximum flank wear (mm)

v c :

Cutting speed (m/min)

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Acknowledgements

The authors would like to thank FA Powertrain Ltd for providing equipment and materials for the experimental tests and also to CAPES (Coordenação de Aperfeiçoamento de Pessoal de Ensino Superior, Processo No. PDE 0333–04–2) for their assistance in developing this project.

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Authors and Affiliations

  1. FA Powertrain, Betim, MG, Brazil

    J. A. B. O. dos Santos

  2. Mechanical and Mechatronics Engineering, Manufacturing Research Centre, Pontifical Catholic University of Minas Gerais, Belo Horizonte, MG, Brazil

    W. F. Sales

  3. Federal Technological Education Centre of Minas Gerais, CEFET MG, Belo Horizonte, MG, Brazil

    S. C. Santos

  4. Faculty of Mechanical Engineering, Federal University of Uberlândia, Uberlândia, MG, Brazil

    A. R. Machado & M. B. da Silva

  5. Machining Research Centre, Department of Engineering Systems, London South Bank University, London, SE 1 0AA, UK

    J. Bonney & E. O. Ezugwu

Authors
  1. J. A. B. O. dos Santos
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  2. W. F. Sales
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  3. S. C. Santos
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  4. A. R. Machado
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  5. M. B. da Silva
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  6. J. Bonney
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  7. E. O. Ezugwu
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Corresponding author

Correspondence to E. O. Ezugwu.

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dos Santos, J.A.B.O., Sales, W.F., Santos, S.C. et al. Tribological evaluation of TiN and TiAlN coated PM-HSS gear cutter when machining 19MnCr5 steel. Int J Adv Manuf Technol 31, 629–637 (2007). https://doi.org/10.1007/s00170-005-0242-3

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  • DOI: https://doi.org/10.1007/s00170-005-0242-3

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