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Studying the effects of coatings on the thermal protection of cutting tools during turning via a nonlinear inverse heat conduction problem

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Abstract

Inserts are significantly affected by heat and mechanical stress in turning processes. Over time, improvements have been made to these inserts to attenuate these impacts. One such enhancement involves applying coatings. While cutting temperatures have been widely studied, there is a lack of information on quantifying the thermal protection offered by coatings on insert substrates and the relationship to tool-chip contacts. This study examines these characteristics, considering factors like the tool-chip contact area, cutting forces, cutting speed, and the presence of coatings. We considered two cutting tools, one uncoated and the other coated with TiCN, Al2O3, and TiN. Regarding the methodology, we measured temperature fluctuations at accessible points on the insert during turning of a nodular cast iron GGG40. These temperature readings were then used to estimate the heat flux at the tool-chip contact area. We employed the adaptive sequential function specification method (ASFSM) for this purpose. Noteworthy aspects of this technique include its ability to handle nonlinearity, and it makes use of multiple temperature sensors to estimate heat flux. Upon comparing the confidence intervals, we observed that the method employed in this study yielded a temperature difference between the numerical and experimental results that was 35% smaller than the maximum variation observed in experimental replicates. This confirms the effectiveness of the method and validates the analyses conducted. Upon evaluating the insert, we observed that the presence of coating reduced the tool-chip contact area. Furthermore, at increased cutting speeds, the coating enhanced the thermal protection of the substrate.

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Data availability

The dataset is available upon reasonable request.

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Acknowledgements

The authors would like to express their gratitude for the financial support provided by the Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES), the Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq), and the Fundação de Amparo á Pesquisa do Estado de Minas Gerais (FAPEMIG).

Funding

This research received financial support from the following Brazilian agencies: CAPES, CNPq, and FAPEMIG.

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Authors and Affiliations

  1. Laboratório de Transferência de Calor (LabTC), Instituto de Engenharia Mecânica (IEM), Universidade Federal de Itajubá (UNIFEI), Itajubá, MG, Brazil

    Diego Corrêa Ferreira, Fernando Viana Avelar Dutra, Rodrigo Gustavo Dourado da Silva & Sandro Metrevelle Marcondes de Lima e Silva

  2. Laboratório de Manufatura e Automação (LMAUT), Instituto de Engenharia de Produção e Gestão (IEPG), Universidade Federal de Itajubá (UNIFEI), Itajubá, MG, Brazil

    João Roberto Ferreira

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  1. Diego Corrêa Ferreira
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  2. Fernando Viana Avelar Dutra
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  3. Rodrigo Gustavo Dourado da Silva
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  4. Sandro Metrevelle Marcondes de Lima e Silva
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Contributions

DCF, FVAD, and RGDdS contributed writing to the methodology, results, analyses, and original draft. SMMdLeS and JRF provided supervision, reviewed the work, and contributed with resources.

Corresponding author

Correspondence to Sandro Metrevelle Marcondes de Lima e Silva.

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Corrêa Ferreira, D., Viana Avelar Dutra, F., Gustavo Dourado da Silva, R. et al. Studying the effects of coatings on the thermal protection of cutting tools during turning via a nonlinear inverse heat conduction problem. Int J Adv Manuf Technol 129, 3009–3026 (2023). https://doi.org/10.1007/s00170-023-12473-z

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