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Dry finishing turning of AA7075 with binary and ternary nitrides and carbides ceramic-coated tools

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Abstract

This research work focus on dry finishing (turning) of AA7075. Newly, emerging alloy target–based ternary PVD–coated tool inserts are compared with non-alloy target–based binary and ternary-coated tool inserts. The coatings include novel alloy target coatings TiAlN (80:20), TiAlN (70:30), and TiAlN (50:50) and non-alloy target coatings TiN and TiCN. One uncoated and five coated tungsten carbide (WC) inserts are analyzed for maximum tool life and minimum surface roughness in dry machining (finish turning) process. Depth of cut, feed rate, and cutting speed are operational parameters optimized against performance parameters (tool life and surface roughness) using a two-stage design of experiment approach. Initial experiments are carried out using L18 (6133) special orthogonal array. General linear model (GLM), linear regression model (LR), and stepwise forward regression model (SFR) are used for analysis. Among alloy target–based PVD–coated tool inserts, TiAlN (50:50) and TiAlN (70:30) performed better in terms of tool life and surface roughness respectively. The TiN-coated tool insert is found as overall superior performing tool insert considering the finished products roughness concerns of aero industry. The optimized solution for TiN is obtained by designing a full factorial experimental configuration. At low feed rate and low cutting speed, high feed rate and low cutting speed, and high feed rate and high cutting speed, approximately 45%, 47%, and 29% higher surface finish can be obtained respectively. Similarly, at low feed rate and low cutting speed and high feed rate and medium cutting speed, approximately 136% and 146% longer tool life can be obtained respectively. A combined saving, i.e., 27% high surface finish, 32% longer tool life and 16% higher material removal rate, can be obtained for optimized setting. Comparing the optimized results with L18 experiments, the optimized solution can give approximately 42% higher surface finish and above 300% longer tool life. Results are discussed on the basis of response surfaces, scanning electron microscopy, and chip roughness profile.

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Abbreviations

AA7075:

Aluminum alloy 7075

WC:

Tungsten carbide

TiN:

Titanium nitride

TiCN:

Titanium carbo nitride

TiAlN (80:20):

Titanium aluminum nitride produced from alloy target with 80% titanium and 20% aluminum

TiAlN (70:30):

Titanium aluminum nitride produced from alloy target with 70% titanium and 30% aluminum

TiAlN (50:50):

Titanium aluminum nitride produced from alloy target with 50% titanium and 50% aluminum

Insert 1:

Uncoated tungsten carbide tool insert

Insert 2:

TiN coated tungsten carbide tool insert

Insert 3:

TiCN coated tungsten carbide tool insert

Insert 4:

TiAlN (80:20) coated tungsten carbide tool insert

Insert 5:

TiAlN (70:30) coated tungsten carbide tool insert

Insert 6:

TiAlN (50:50) coated tungsten carbide tool insert

GLM:

General linear model

LR:

Linear regression

SFR:

Stepwise forward regression

CMM:

Coordinate measuring machine

PVD:

Physical vapor deposition

DOC:

Depth of cut

FR:

Feed rate

CS:

Cutting speed

CR:

Confirmatory run

FS:

Factor selection

RSM:

Response surface methodology

SEM:

Scanning electron microscopy

BUE:

Build-up edges

DOE:

Design of experiments

MRR:

Material removal rate

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Authors and Affiliations

  1. Department of Mechanical Engineering, University of Engineering & Technology, Lahore, 54890, Pakistan

    Syed Wasim Hassan Zubair, Syed Muhammad Arafat, Ghulam Moeen Uddin & Nasir Hayat

  2. Department of Mechanical Engineering, Faculty of Engineering & Technology, The University of Lahore, Lahore, 54000, Pakistan

    Syed Muhammad Arafat

  3. Department of Industrial and Manufacturing Engineering, University of Engineering and Technology, Lahore, 54890, Pakistan

    Sarmad Ali Khan

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  1. Syed Wasim Hassan Zubair
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Correspondence to Sarmad Ali Khan.

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Zubair, S.W.H., Arafat, S.M., Khan, S.A. et al. Dry finishing turning of AA7075 with binary and ternary nitrides and carbides ceramic-coated tools. Int J Adv Manuf Technol 129, 65–87 (2023). https://doi.org/10.1007/s00170-023-12105-6

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