Skip to main content
SpringerLink
Log in

Surface integrity evolution and wear evolution of the micro-blasted coated tool in high-speed turning of Ti6Al4V

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

    We’re sorry, something doesn't seem to be working properly.

    Please try refreshing the page. If that doesn't work, please contact support so we can address the problem.

Abstract

The coated tool is one of the most widely used cutters in the processing of titanium alloy. The wear of the coated tool is influenced by its surface integrity which can be improved by surface treatment, such as micro-blasting. The experiment of high-speed dry turning of titanium alloy Ti6Al4V (TC4) is carried out by the PVD-TiAlN coated carbide tools which are untreated and micro-blasted. For the coated tool, the evolution of the tool surface integrity, including tool surface roughness, tool surface topography, tool surface hardness, and tool surface residual stress, is studied at different wear stages. Moreover, the evolution of tool wear is analyzed at different wear stages. Then, the influence of tool surface integrity on tool wear is investigated. It is suggested that the tool surface integrity and wear resistance of the treated tool is improved. The change of tool wear is consistent with the change of coating surface integrity. That is to say, the better tool surface integrity is, the less tool wear will be. In addition, the main tool wear mechanisms are adhesive wear and oxidative wear. In the end, the stable wear stage of treated tools is prolonged, and the tool life is increased by more than 40%.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13

Similar content being viewed by others

Data availability

The data sets supporting the results of this article are included within the article and its additional files.

References

  1. Xie RZ, Lin NM, Zhou P, Zou JJ, Han PJ, Wang ZH, Tang B (2018) Surface damage mitigation of TC4 alloy via micro arc oxidation for oil and gas exploitation application: characterizations of microstructure and evaluations on surface performance. Appl Surf Sci 436:467–476. https://doi.org/10.1016/j.apsusc.2017.12.047

    Article  Google Scholar 

  2. Biksa A, Yamamoto K, Dosbaeva G, Veldhuis SC, FoxRabinovich GS, Elfizy A, Wagg T, Shuster LS (2010) Wear behavior of adaptive nano-multilayered AlTiN/MexN PVD coatings during machining of aerospace alloys. Tribol Int 43:1491–1499. https://doi.org/10.1016/j.triboint.2010.02.008

    Article  Google Scholar 

  3. Wang H, Zhao KX, Chu XR, Zhao B, Gao J (2019) Constitutive modeling and microscopic analysis of TC4 alloy sheet at elevated temperature. Results Phys 13:2–11. https://doi.org/10.1016/j.rinp.2019.102332

    Article  Google Scholar 

  4. Shao L, Xie GL, Liu XH, Wu Y, Yu JB, Hao ZF, Lu WR, Liu X (2020) Combustion behavior and mechanism of TC4 and TC11 alloys. Corros Sci 168:1–12. https://doi.org/10.1016/j.corsci.2020.108564

    Article  Google Scholar 

  5. Abdoos M, Bose B, Rawal S, Arif AFM, Veldhuis SC (2020) The influence of residual stress on the properties and performance of thick TiAlN multilayer coating during dry turning of compacted graphite iron. Wear 203342:454–455. https://doi.org/10.1016/j.wear.2020.203342

    Article  Google Scholar 

  6. Chen L, Paulitsch J, Du Y, Mayrhofer PH (2012) Thermal stability and oxidation resistance of Ti-Al-N coatings. Surf Coat Technol 206:2954–2960. https://doi.org/10.1016/j.surfcoat.2011.12.028

    Article  Google Scholar 

  7. Zhao T, Shi YY, Sampsa L, Zhou JM (2017) Investigation of the effect of grinding parameters on surface quality in grinding of TC4 titanium alloy. Procedia Manuf 11:2131–2138. https://doi.org/10.1016/j.promfg.2017.07.344

    Article  Google Scholar 

  8. Hong SY, Ding YC (2001) Cooling approaches and cutting temperatures in cryogenic machining of Ti-6Al-4V. Int J Mach Tools Manuf 41:1417–1437. https://doi.org/10.1016/S0890-6955(01)00026-8

    Article  Google Scholar 

  9. Panjan P, Cekada M, Panjan M, Kek-Merl D, Zupanic F, Curkovic L, Paskvale S (2012) Surface density of growth defects in different PVD hard coatings prepared by sputtering. Vacuum 86:794–798. https://doi.org/10.1016/j.vacuum.2011.07.013

    Article  Google Scholar 

  10. Chang KS, Zheng GM, Li Y, Liu HB, Zhao GX (2020) Effects of wet micro-blasting on surface integrity and cutting performance of TiAlN coating tools, Mater. Rep. accepted.

  11. Daure JL, Voisey KT, Shipway PH, Stewart DA (2017) The effect of coating architecture and defects on the corrosion behavior of a PVD multilayer Inconel 625/Cr coating. Surf Coat Technol 324:403–412. https://doi.org/10.1016/j.surfcoat.2017.06.009

    Article  Google Scholar 

  12. Zhou WP, Liang JC, Zhang FG, Mu JG, Zhao HB (2014) A comparative research on TiAlN coatings reactively sputtered from powder and from smelting TiAl targets at various nitrogen flow rates. Appl Surf Sci 313:10–18. https://doi.org/10.1016/j.apsusc.2014.05.053

    Article  Google Scholar 

  13. Bouzakis KD, Tsouknidas A, Skordaris G, Bouzakis E (2011) Optimization of wet or dry micro-blasting on PVD films by various Al2O3 grain sizes for improving the coated tools’ cutting performance. Tribol Int 33:49–56. https://doi.org/10.1016/j.cirp.2011.03.012

    Article  Google Scholar 

  14. Jacob A, Gangopadhyay S, Satapathy A, Mantry S, Jha BB (2017) Influences of micro-blasting as surface treatment technique on properties and performance of AlTiN coated tools. J Manuf Process 29:407–418. https://doi.org/10.1016/j.jmapro.2017.08.013

    Article  Google Scholar 

  15. Geng Z, Shi GL, Shao TM, Liu Y, Duan DL, Reddyhoff T (2019) Tribological behavior of patterned TiAlN coatings at elevated temperatures. Surf Coat Technol 364:99–114. https://doi.org/10.1016/j.surfcoat.2019.02.076

    Article  Google Scholar 

  16. Deng JX, Liu AH (2013) Dry sliding wear behavior of PVD TiN, Ti55Al45N, and Ti35Al65N coatings at temperatures up to 600 degrees C. Int J Refract Met Hard Mater 41:241–249. https://doi.org/10.1016/j.ijrmhm.2013.04.008

    Article  Google Scholar 

  17. Kong DJ, Guo HY, Wang WC (2016) Effects of loadings on friction and wear behaviors of cathodic arc ion plating AlTiN coating at high temperature. Tribol Trans 59:605–612. https://doi.org/10.1080/10402004.2015.1094842

    Article  Google Scholar 

  18. Hou MD, Mou WP, Yan GH, Song G, Wu Y, Ji W, Jiang ZX, Wang W, Qian CK, Cai ZP (2020) Effects of different distribution of residual stresses in the depth direction on cutting performance of TiAlN coated WC-10wt%Co tools in milling Ti-6Al-4V. Surf Coat Technol 397:125972. https://doi.org/10.1016/j.surfcoat.2020.125972

    Article  Google Scholar 

  19. Chu K, Shum PW, Shen YG (2006) Substrate bias effects on mechanical and tribological properties of substitution solid solution (Ti, Al)N films prepared by reactive magnetron sputtering. Mater Sci Eng B 131:62–71. https://doi.org/10.1016/j.mseb.2006.03.036

    Article  Google Scholar 

  20. Staia MH, D'Alessandria M, Quinto DT, Roudet F, Astort MM (2006) High-temperature tribological characterization of commercial TiAlN coatings. J Phys Condens Matter 18:S1727–S1736. https://doi.org/10.1016/j.surfcoat.2004.08.221

    Article  Google Scholar 

  21. Qi ZB, Sun P, Zhu FP, Wu ZT, Liu B, Wang ZC, Peng DL, Wu CH (2013) Relationship between tribological properties and oxidation behavior of Ti0.34-Al0.66-N coatings at elevated temperature up to 900°C. Surf Coat Technol 231:267–272. https://doi.org/10.1016/j.surfcoat.2012.02.017

    Article  Google Scholar 

  22. Skordaris G, Bouzakis KD, Kotsanis T, Charalampous P, Bouzakis E, Breidenstein B, Bergmann B, Denkena B (2017) Effect of PVD film’s residual stresses on their mechanical properties, brittleness, adhesion and cutting performance of coated tools. CIRP J Manuf Sci Technol 18:145–151. https://doi.org/10.1016/j.cirpj.2016.11.003

    Article  Google Scholar 

  23. Xu YL, Dini D (2020) Capturing the hardness of coating systems across the scales. Surf Coat Technol 394:125860. https://doi.org/10.1016/j.surfcoat.2020.125860

    Article  Google Scholar 

  24. Sui XD, Lin GJ, Qin XS, Yu HD, Zhou XK, Wang K, Wang Q (2016) Relationship of microstructure, mechanical properties and titanium cutting performance of TiAlN/TiAlSiN composite coated tool. Ceram Int 42:7524–7532. https://doi.org/10.1016/j.ceramint.2016.01.159

    Article  Google Scholar 

  25. Nouari M, Ginting A (2006) Wear characteristics and performance of multi-layer CVD-coated alloyed carbide tool in dry end milling of titanium alloy. Surf Coat Technol 200:5663–5676. https://doi.org/10.1016/j.surfcoat.2005.07.063

    Article  Google Scholar 

  26. Castanho JM, Vieira MT (2003) Effect of ductile layers in mechanical behavior of TiAlN thin coatings. J Mater Process Technol 143-144:352–357. https://doi.org/10.1016/S0924-0136(03)00454-0

    Article  Google Scholar 

  27. Du LX (2016) Research on titanium alloy TC4 cutting technology. Dalian University of Technology, Dalian, Dissertation (in Chinese)

    Google Scholar 

  28. Chang KS, Zheng GM, Li Y, Li XW, Xu RF (2020) Wear evolution mechanism of PVD-TiAlN coated carbide tool in high-speed dry turning of TC4 alloy. Mod Mach Tool Autom Manuf Tech 9:140–146. https://doi.org/10.13462/j.cnki.Mmtamt.2020.09.031

    Article  Google Scholar 

  29. Zheng GM, Zhao GY, Cheng X, Xu RF, Zhao J, Zhang HQ (2018) Frictional and wear performance of TiAlN/TiN coated tool against high-strength steel. Ceram Int 44:6878–6885. https://doi.org/10.1016/j.ceramint.2018.01.113

    Article  Google Scholar 

  30. Li AH, Zhao J, Zang J, Zheng W (2016) Design and simulation of thermal residual stresses of coatings on WC-Co cemented carbide cutting tool substrate[J]. J Mech Sci Technol 30(8):3777–3783. https://doi.org/10.1007/s12206-016-0430-0

    Article  Google Scholar 

  31. Hou MD, Mou WP, Yan GH, Song G, Wu Y, Ji W, Jiang ZX, Wang W, Qian CK, Cai ZP (2020) Effects of different distribution of residual stresses in the depth direction on cutting performance of TiAlN coated WC-10wt%Co tools in milling Ti-6Al-4V[J]. Surf Coat Technol 397:397. https://doi.org/10.1016/j.surfcoat.2020.125972

    Article  Google Scholar 

  32. Yan P, Deng JX, Cui HB, Ai X, Zhao J (2010) Finite element analysis of thermal stress in multi-arc ion plated ZrTiN hard coatings [J]. Adv Mater Res 1037:369–373. https://doi.org/10.4028/www.scientific.net/AMR.139-141.36

    Article  Google Scholar 

  33. Zheng GM, Li L, Li ZY, Zhao J, Niu ZW (2018) Wear mechanisms of coated tools in high-speed hard turning of high strength steel. Int J Adv Manuf Technol 94:4553–4563. https://doi.org/10.1007/s00170-017-1132-1

    Article  Google Scholar 

Download references

Acknowledgements

We are grateful to the National Natural Science Foundation of China (No. 52075306), the National Key Research and Development Program of China (No. 2018YFB2001400, 2018YFB2002202), the Zibo City-Shandong University of Technology Cooperative Projects (No. 2018ZBXC003), the Natural Science Foundation of Shandong Province (ZR2020ME156) for their support to this work.

Author information

Authors and Affiliations

  1. School of Mechanical Engineering, Shandong University of Technology, 266 West Xincun Road, Zibo, 255000, China

    Kaishuo Chang, Guangming Zheng, Xiang Cheng, Rufeng Xu, Yang Li, Zhou Yu & Xianhai Yang

Authors
  1. Kaishuo Chang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Guangming Zheng
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Xiang Cheng
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Rufeng Xu
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Yang Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Zhou Yu
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Xianhai Yang
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Kaishuo Chang: Conceptualization, methodology, formal analysis, investigation, writing—original draft, writing—review and editing. Guangming Zheng: Investigation, formal analysis, writing—review and editing, supervision. Xiang Cheng: Writing—review and editing. Rufeng Xu: Methodology, formal analysis. Yang Li: Methodology, investigation, formal analysis. Zhou Yu: Conceptualization, methodology. Xianhai Yang: Writing—review and editing.

Corresponding author

Correspondence to Guangming Zheng.

Ethics declarations

Ethics approval

Not applicable

Consent to participate

Not applicable

Consent for publication

The copyright permission has been taken, and consent to submit has been received explicitly from all authors.

Competing interests

The authors declare no competing interests.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Chang, K., Zheng, G., Cheng, X. et al. Surface integrity evolution and wear evolution of the micro-blasted coated tool in high-speed turning of Ti6Al4V. Int J Adv Manuf Technol 115, 603–616 (2021). https://doi.org/10.1007/s00170-021-07227-8

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-021-07227-8

Keywords

Search

Navigation