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Drilling of nodular cast iron with a novel SiO2 coating deposited by sol-gel process in HSS drill

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Abstract

The present study proposes a novel coating applied on high-speed steel (HSS) drills, thinner and less expensive than the commercial ones. This new coating consists in a silicon dioxide (SiO2) deposited by sol-gel process, and its performance was studied by means of drilling tests in nodular cast iron. For comparison purposes, two other cutting tools were also evaluated: uncoated and TiN-coated by physical vapor deposition process. Four outputs were investigated: thrust force, hole average surface roughness, hole average diameter (DA), and tool wear (VBBmax). Analysis of variance (ANOVA) was applied to determine the influences of the coatings and drilling parameters on the cutting performances. The results indicated that the SiO2 coating achieved performances significantly superior to the uncoated tools. They also behaved close to the commercial TiN coating in some aspects. Scanning electron microscopy (SEM) analysis showed predominant flank wear in all the uncoated and coated tools. The “number of holes/maximum flank wear (VBBmax)” ratios were calculated, indicating a performance 315% better for the SiO2-coated tool when compared to the uncoated one. Therefore, the deposition of SiO2 by sol-gel method is a promising technique to coat rapidly and efficiently cutting tools, including for tools of complex geometries such as drills.

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Funding

This study was partly financed by the Coordenação de Aperfeiçoamento de Pessoal de Nível Superior - Brasil (CAPES) - Finance Code 001. This study also received financial support from the agencies FAPEMIG (Fundação de Amparo à Pesquisa do Estado de Minas Gerais) and CNPq (Conselho Nacional de Desenvolvimento Científico e Tecnológico).

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Authors and Affiliations

  1. Department of Production Engineering, Federal University of Minas Gerais, Av. Presidente Antônio Carlos, 6627, Belo Horizonte, CEP, 31270-901, Brazil

    Natália Fernanda Santos Pereira

  2. Department of Mechanical Engineering, Federal University of Minas Gerais, Av. Presidente Antônio Carlos, 6627, Belo Horizonte, CEP, 31270-901, Brazil

    Juan Carlos Campos Rubio, Anderson Júnior dos Santos & Marcelo Araújo Câmara

  3. Department of Materials and Construction Engineering, Federal University of Minas Gerais, Av. Presidente Antônio Carlos, 6627, Belo Horizonte, CEP, 31270-901, Brazil

    Manuel Houmard

  4. Department of Mechanical Engineering, University of São Paulo, Av. Trabalhador São-Carlense, 400, São Carlos, CEP, 13566-590, Brazil

    Alessandro Roger Rodrigues

Authors
  1. Natália Fernanda Santos Pereira
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  2. Juan Carlos Campos Rubio
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  3. Anderson Júnior dos Santos
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  4. Manuel Houmard
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  5. Marcelo Araújo Câmara
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  6. Alessandro Roger Rodrigues
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Correspondence to Natália Fernanda Santos Pereira.

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Pereira, N.F.S., Rubio, J.C.C., dos Santos, A.J. et al. Drilling of nodular cast iron with a novel SiO2 coating deposited by sol-gel process in HSS drill. Int J Adv Manuf Technol 105, 4837–4849 (2019). https://doi.org/10.1007/s00170-019-04429-z

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