Tool Wear Behavior in Milling of Hardened Custom 465 Steel
With current advancements in hard-milling technology, tool wear and surface integrity have turn out to be a vital attention to improve machining efficiency and the quality of machined components. The aspiration of this current research paper is to examine tool wear and chip morphology when machining hardened Custom 465 (~55HRC) steel with uncoated, commercial TiAlN, and nanolayer silicon nitride coated inserts. The tests were carried out using constant cutting speed of 150 m/min, feed of 0.1 mm/tooth, and depth of cut of 0.3 mm in dry atmosphere. Wear measurements were made with an optical microscope aided by imaging software. Subsequently after each cutting pass, the milling process was clogged; the tool was detached from the tool holder and carried to the optical microscope where the wear of the VBmax flank wear was measured. Likewise, chips were collected and examined during each cutting pass to study its morphology. Flank wear of 0.5 mm was postulated as a denial standard. Wear investigation was executed using an optical microscope for flank and rake faces. Several wear patterns such as abrasion, flank wear, and unwarranted chipping on the tool edge have been studied. The nanolayer silicon nitride coating offers the finest wear resistance in machining and hence responsible for the extended life with carbide inserts.
KeywordsTool wear Coated inserts Flank wear Wear patterns
We would like to express our thanks to DRDL, Hyderabad for funding this project (Grant No. 42141/2015). We also acknowledge the faculty members of Center for advanced tooling and precision dies and PSG Institute of Advanced Studies, Coimbatore.
- 1.Takacs, M., Farkas, B.Z.: Hard cutting of AISI D2 steel, No. 176, pp. 1–7 (2014)Google Scholar
- 2.Lajis, M.A., Amin, A.K.M.N., Karim,A.N.M., Hafiz, A.M.K.: Preheating in end milling of AISI D2 hardened steel with coated carbide inserts (2008)Google Scholar
- 4.Gopalsamy, B.M., Mondal, B.: Investigations on hard machining of Impax Hi Hard tool steel, pp. 145–165 (2009)Google Scholar
- 6.Fox-rabinovich, G.S., Yamamoto, K., Beake, B.D., Kovalev, A.I., Aguirre, M.H., Veldhuis, S.C.: Surface & coatings technology emergent behavior of nano-multilayered coatings during dry high-speed machining of hardened tool steels. Surf. Coat. Technol. 204(21–22), 3425–3435 (2010)CrossRefGoogle Scholar
- 7.Fox-Rabinovich, G.S., Yamamoto, K., Beake, B.D.: Hierarchical adaptive nanostructured PVD coatings for extreme tribological applications: the quest for nonequilibrium states and emergent behavior, Vol. 043001 (2012)Google Scholar
- 8.Ducros, C., Cayron, C., Sanchette, F.: Multilayered and nanolayered hard nitride thin films deposited by cathodic arc evaporation. Part 1 : deposition, morphology and microstructure, Vol. 201, pp. 136–142 (2006)Google Scholar