Skip to main content
SpringerLink
Log in

Study of wear behavior and tool life in different taps during the internal threading of a nodular iron engine crankshaft

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

Abstract

Threading is a process that generates internal and external threads, and it is widely used in various applications in industries as threads can be found in almost all industrial mechanical component assemblies due to precision and speed. In machining, threading is one of the most critical processes. The machining process focused on this study is responsible for the thread to fix the engine gear on the crankshaft. The modernization of internal combustion engines has required evolution concerning dimensional accuracy unprecedented in the mechanical industry and better mechanical and tribological properties at a low cost. One solution that has been researched in depth to overcome the threading machining problems is to use coated tools. Therefore, this study aims to analyze the performance of different thread tapping tools regarding cutting tool life cycle and wear mechanisms during the internal threading of a nodular iron engine crankshaft. The tools used were sintered uncoated High-Speed Steel – HSS-PM, coated HSS-PM (TiN), and HSS-PM (TiCN). The wear measurement on each cutting core was evaluated using a laser beam and calculated by a measuring equipment software. It was observed/shown that the wear mechanism for the HSS-PM tool is the plastic deformation with the formation of cracks in regions of the Co/Cr/C binder. Moreover, the tools coated with TiN and TiCN showed abrasive wear of the coating and localized peeling, especially at some zone where it had low substrate adhesion, tool wear. The sharp softening of the HSS-PM tool after fracturing in 2100 threads may be caused by the low temperature reached in the cut or the presence of W, V, and C in the microstructure. HSS-PM (TiCN) taps performed better than HSS-PM (TiN) (21% better), as well as uncoated HSS-PM (86% better).

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

Similar content being viewed by others

Availability of data and materials

The datasets obtained during the current work are available from the corresponding author upon request.

Abbreviations

BUE:

Built-Up Edge

COF:

Coefficient Of Friction

TiCN:

Titanium Carbon Nitride

TiAlN:

Titanium Aluminum Nitride

AlCr:

Aluminum Chromium

AlTiN:

Aluminum Titanium Nitride

TiN:

Titanium Nitride

PVD:

Physical Vapor Deposition

CVD:

Chemical Vapor Deposition

HSS-PM:

High-Speed Steel Powder Metallurgy

DLC:

Diamond-Like Carbon

C:

Carbon

Si:

Silicon

Mn:

Manganese

P:

Phosphorus

S:

Sulfur

Mg:

Magnesium

Cu:

Copper

HV:

Hardness Vickers

ISO:

International Standard Organization

SEM:

Scanning Electronic Microscope

FEG:

Field Emission Gun

H:

Hardness

E:

Young's modulus

CNC:

Computer Numerical Control

\({A}_{P}\) :

Area of the clearance face for each fillet

\({A}_{SP}\) :

Worn area of the clearance face for the

W:

Tungsten

Cr:

Chromium

V:

Vanadium

Mo:

Molybdenum

EDS:

Energy Dispersive X-ray Spectroscopy

Ti:

Titanium

Fe:

Iron

References

  1. de Oliveira JA, Ribeiro Filho SLM, Brandão LC (2019) Investigation of the influence of coating and the tapered entry in the internal forming tapping process. Int J Adv Manuf Technol 101:1051–1063. https://doi.org/10.1007/s00170-018-3011-9

    Article  Google Scholar 

  2. Fernandes GHN, Lopes GHF, Barbosa LMQ, Martins PS, Machado ÁR (2021) Wear mechanisms of diamond-like carbon coated tools in tapping of AA6351 T6 aluminium alloy. Procedia Manuf 53:293–298. https://doi.org/10.1016/j.promfg.2021.06.032

    Article  Google Scholar 

  3. Leach F, Kalghatgi G, Stone R, Miles P (2020) The scope for improving the efficiency and environmental impact of internal combustion engines. Transp Eng 1:100005. https://doi.org/10.1016/j.treng.2020.100005

    Article  Google Scholar 

  4. Conway G, Joshi A, Leach F, García A, Senecal PK (2021) A review of current and future powertrain technologies and trends in 2020. Transp Eng 5:100080. https://doi.org/10.1016/j.treng.2021.100080

    Article  Google Scholar 

  5. Pascoal ET, Delamaro MC, Ibusuki U, Tsukada O, Rocha HM (2017) The new Brazilian automotive policy and its impact on the competitiveness of multinational automobile and auto parts manufacturers. Int J Automot Technol Manag 17:225. https://doi.org/10.1504/IJATM.2017.086405

    Article  Google Scholar 

  6. Yang YM (2018) A study on characteristics of dimensional accuracy using planning number of machining in machining center. Korean Soc Manuf Process Eng 17:61–67. https://doi.org/10.14775/ksmpe.2018.17.6.061

    Article  Google Scholar 

  7. Taub A, De Moor E, Luo A, Matlock DK, Speer JG, Vaidya U (2019) Materials for automotive lightweighting. Annu Rev Mater Res 49:327–359. https://doi.org/10.1146/annurev-matsci-070218-010134

    Article  Google Scholar 

  8. Madhan Kumar S, Govindaraj E, Balamurugan D, Daniel F (2021) Design analysis and fabrication of automotive transmission gearbox using hollow gears for weight reduction. Mater Today Proc 45:6822–6832. https://doi.org/10.1016/j.matpr.2020.12.1005

    Article  Google Scholar 

  9. Dekker L, Tonn B (2016) Occurrence and behaviour of Mo containing precipitates in nodular cast iron at high temperatures. Int J Cast Met Res 29:85–91. https://doi.org/10.1179/1743133615Y.0000000024

    Article  Google Scholar 

  10. Vinayagamoorthy R (2018) A review on the machining of fiber-reinforced polymeric laminates. J Reinf Plast Compos 37:49–59. https://doi.org/10.1177/0731684417731530

    Article  Google Scholar 

  11. Aslantas K, Ucun I (2009) The performance of ceramic and cermet cutting tools for the machining of austempered ductile iron. Int J Adv Manuf Technol 41:642–650. https://doi.org/10.1007/s00170-008-1528-z

    Article  Google Scholar 

  12. Wang B, Barber GC, Tao C, Sun X, Ran X (2018) Characteristics of tempering response of austempered ductile iron. J Mater Res Technol 7:198–202. https://doi.org/10.1016/j.jmrt.2017.08.011

    Article  Google Scholar 

  13. Meier L, Hofmann M, Saal P, Volk W, Hoffmann H (2013) In-situ measurement of phase transformation kinetics in austempered ductile iron. Mater Charact 85:124–133. https://doi.org/10.1016/j.matchar.2013.09.005

    Article  Google Scholar 

  14. Ba ECT, Dumont MR, Martins PS, Drumond RM, Martins da Cruz MP, Vieira VF (2021) Investigation of the effects of skewness Rsk and kurtosis Rku on tribological behavior in a pin-on-disc test of surfaces machined by conventional milling and turning processes. Mater Res 24:1–14. https://doi.org/10.1590/1980-5373-mr-2020-0435

    Article  Google Scholar 

  15. Martins PS, Carneiro JRG, Ba ECT, Vieira VF, Amaral DB, da Cruz NC (2022) Study on the Tribological behavior of wear and friction coefficient on AISI M35 high-speed steel with and without DLC coating. Mater Res 25:e20200577. https://doi.org/10.1590/1980-5373-mr-2020-0577

    Article  Google Scholar 

  16. Liu Y, Zhao J (2018) Study on Vibration Tapping for SiCp/Al Particle-reinforced Metal Matrix Composite. MATEC Web Conf 228:04005. https://doi.org/10.1051/matecconf/201822804005

    Article  Google Scholar 

  17. Gil-Del-Val A, Diéguez PM, Arizmendi M, Estrems M (2015) Experimental study of tapping wear mechanisms on nodular cast iron. Procedia Eng 132:190–196. https://doi.org/10.1016/j.proeng.2015.12.469

    Article  Google Scholar 

  18. Gil Del Val A, Veiga F, Suárez A, Arizmendi M (2020) Thread quality control in high-speed tapping cycles. J Manuf Mater Process 4:9. https://doi.org/10.3390/jmmp4010009

    Article  Google Scholar 

  19. Martins PS, GonçalvesCarneiro JR, Ba ECT, Vieira VF (2021) Study on roughness and form errors linked with tool wear in the drilling process of an Al-Si alloy under high cutting speed using coated diamond-like carbon high-speed steel drill bits. J Manuf Process 62:711–719. https://doi.org/10.1016/j.jmapro.2021.01.006

    Article  Google Scholar 

  20. Klocke F, Krieg T (1999) Coated tools for metal cutting – features and applications. CIRP Ann 48:515–525. https://doi.org/10.1016/S0007-8506(07)63231-4

    Article  Google Scholar 

  21. Bobzin K (2017) High-performance coatings for cutting tools. CIRP J Manuf Sci Technol 18:1–9. https://doi.org/10.1016/j.cirpj.2016.11.004

    Article  Google Scholar 

  22. Sousa VFC, Silva FJG (2020) Recent advances on coated milling tool technology—a comprehensive review. Coatings 10:235. https://doi.org/10.3390/coatings10030235

    Article  Google Scholar 

  23. Gupta KM, Ramdev K, Dharmateja S, Sivarajan S (2018) Cutting characteristics of PVD coated cutting tools. Mater Today Proc 5:11260–11267. https://doi.org/10.1016/j.matpr.2018.02.092

    Article  Google Scholar 

  24. Elosegui I, Alonso U, Lopez de Lacalle LN (2017) PVD coatings for thread tapping of austempered ductile iron. Int J Adv Manuf Technol 91:2663–2672. https://doi.org/10.1007/s00170-016-9963-8

    Article  Google Scholar 

  25. Othman MF, Bushroa AR, Abdullah WNR (2015) Evaluation techniques and improvements of adhesion strength for TiN coating in tool applications: a review. J Adhes Sci Technol 29:569–591. https://doi.org/10.1080/01694243.2014.997379

    Article  Google Scholar 

  26. Uddin GM, Joyia FM, Ghufran M, Khan SA, Raza MA, Faisal M, Arafat SM, Zubair SWH, Jawad M, Zafar MQ, Irfan M, Waseem B, Chaudhry IA, Zeid I (2021) Comparative performance analysis of cemented carbide, TiN, TiAlN, and PCD coated inserts in dry machining of Al 2024 alloy. Int J Adv Manuf Technol 112:1461–1481. https://doi.org/10.1007/s00170-020-06315-5

    Article  Google Scholar 

  27. Chuan SP, Ghani JA, Tomadi SH, Hassan CHC (2012) Analysis of Ti-base hard coating performance in machining process: A review. J Appl Sci 12:1882–1890. https://doi.org/10.3923/jas.2012.1882.1890

    Article  Google Scholar 

  28. Jindal PC, Santhanam AT, Schleinkofer U, Shuster AF (1999) Performance of PVD TiN, TiCN, and TiAlN coated cemented carbide tools in turning. Int J Refract Met Hard Mater 17:163–170. https://doi.org/10.1016/S0263-4368(99)00008-6

    Article  Google Scholar 

  29. Zhao J, Liu Z, Wang B, Hu J, Wan Y (2021) Tool coating effects on cutting temperature during metal cutting processes: comprehensive review and future research directions. Mech Syst Signal Process 150:107302. https://doi.org/10.1016/j.ymssp.2020.107302

    Article  Google Scholar 

  30. Martins PS, Almeida MagalhãesJúnior PA, GonçalvesCarneiro JR, Talibouya Ba EC, Vieira VF (2022) Study of Diamond-Like Carbon coating application on carbide substrate for cutting tools used in the drilling process of an Al–Si alloy at high cutting speeds. Wear. https://doi.org/10.1016/j.wear.2022.204326

    Article  Google Scholar 

  31. Barooah RK, Paiva JM, Arif AFM, Rawal S, Bose B, Veldhuis SC (2021) Investigation on wear mechanisms of PVD coatings for form taps in threading of Al–Si alloy. Wear 464–465:203528. https://doi.org/10.1016/j.wear.2020.203528

    Article  Google Scholar 

  32. Gil Del Val A, Veiga F, Pereira O, Lopez De Lacalle LN (2020) Threading performance of different coatings for high speed steel tapping. Coatings 10:464. https://doi.org/10.3390/coatings10050464

    Article  Google Scholar 

  33. de Freitas SA, Vieira JT, Filho SLMR, Brandão LC (2019) Experimental investigation of tapping in CFRP with analysis of torque-tension resistance. Int J Adv Manuf Technol 104:757–766. https://doi.org/10.1007/s00170-019-03955-0

    Article  Google Scholar 

  34. Bhargava AK, Banerjee MK (2017) 2.2 Hardenability of steel. Compr Mater Finish 50–70. https://doi.org/10.1016/B978-0-12-803581-8.09186-4

  35. Podgornik B, Sedlaček M, Žužek B, Guštin A (2020) Properties of tool steels and their importance when used in a coated system. Coatings 10:265. https://doi.org/10.3390/coatings10030265

    Article  Google Scholar 

  36. Diez-Pastor JF, Gil Del Val A, Veiga F, Bustillo A (2021) High-accuracy classification of thread quality in tapping processes with ensembles of classifiers for imbalanced learning. Meas J Int Meas Confed 168:108328. https://doi.org/10.1016/j.measurement.2020.108328

    Article  Google Scholar 

  37. Gil Del Val A, Fernández J, Del Castillo E, Arizmendi M, Veiga F (2013) Monitoring of thread quality when tapping nodular cast iron with TiN-coated HSS cutting taps. Int J Adv Manuf Technol 69:1273–1282. https://doi.org/10.1007/s00170-013-5078-7

    Article  Google Scholar 

  38. Ramos-Moore E, Espinoza C, Coelho RS, Pinto H, Brito P, Soldera F, Mücklich F, Garcia JL (2014) Investigations on thermal stresses of a graded Ti(C, N) coating deposited on WC-Co hardmetal. Adv Mater Res 996:848–854. https://doi.org/10.4028/www.scientific.net/AMR.996.848

    Article  Google Scholar 

  39. Mills B (1996) Recent developments in cutting tool materials. J Mater Process Technol 56:16–23. https://doi.org/10.1016/0924-0136(95)01816-6

    Article  Google Scholar 

  40. Qi W, Fu S, Li T, Ye F, Guan S, Chen S (2021) Investigation of preparation and properties of TiCN coatings by reactive plasma spraying. J Phys Conf Ser 1983:012103. https://doi.org/10.1088/1742-6596/1983/1/012103

    Article  Google Scholar 

Download references

Acknowledgements

The authors would like to thank the Pontifícia Universidade Católica de Minas Gerais; STELLANTIS LATAM (Betim, Minas Gerais, Brazil) for the availability of materials and analysis laboratories; and colleagues Breno Siqueira from Emuge and Wandeir Braga from Guhring for preparing and supplying all the tools that were needed.

Funding

This study was funded by CAPES, Coordination for the Improvement of Higher Education Personnel, Finance Code 001, which supported this work [Brasília, Brazil, CEP: 70.040–031, CNPJ: 00889834/0001–08].

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Pontifícia Universidade Católica de Minas Gerias, Av. Dom José Gaspar 500, Belo Horizonte, Minas Gerais, CEP 30535-610, Brazil

    Paulo Sérgio Martins, Josué Olímpio dos Santos, José Rubens Gonçalves Carneiro, Gilmar Cordeiro da Silva & Cádmo Augusto Rodrigues Dias

  2. Graduate Program in Mechanical Engineering, Centro Federal de Educação Tecnológica de Minas Gerais, Av. Amazonas 7675, Nova Gameleira, Belo Horizonte, Minas Gerais, CEP: 30510-000, Brazil

    Vitor Ferreira Vieira

  3. Mechanical Engineering Faculty, Universidade Federal de Uberlândia, Av. João Naves de Ávila Avenue 2121, Uberlândia, Minas Gerais, CEP 38408-100, Brazil

    Gustavo Henrique Nazareno Fernandes

  4. Graduate Program in Materials Engineering, Centro Federal de Educação Tecnológica de Minas Gerias, Av. Amazonas 5253, Nova Suíça, Belo Horizonte, Minas Gerais, CEP 30421-169, Brazil

    Elhadji Cheikh Talibouya Ba

Authors
  1. Paulo Sérgio Martins
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Josué Olímpio dos Santos
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. José Rubens Gonçalves Carneiro
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Gilmar Cordeiro da Silva
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Cádmo Augusto Rodrigues Dias
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Vitor Ferreira Vieira
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Gustavo Henrique Nazareno Fernandes
    View author publications

    You can also search for this author in PubMed Google Scholar

  8. Elhadji Cheikh Talibouya Ba
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Paulo Sérgio Martins.

Ethics declarations

Ethics approval

This article requires informed consent of the authors; it does not have any disclosure of potential conflicts of interest and does not involve human and/or animal participants.

Consent to participate

The authors declare that they consent to participate in this paper.

Consent to publish

The authors declare that they consent to publish this paper.

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

Martins, P.S., dos Santos, J.O., Carneiro, J.R.G. et al. Study of wear behavior and tool life in different taps during the internal threading of a nodular iron engine crankshaft. Int J Adv Manuf Technol 120, 7803–7814 (2022). https://doi.org/10.1007/s00170-022-09290-1

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-022-09290-1

Keywords

Search

Navigation