Coated tools constitute the majority of the tools applied in material removal processes, rendering the employment of uncoated ones as an exception. A broad growing market of coated cutting tools has been developed. Moreover, numerous material- and manufacturing-engineers have joint their expertise, aiming at developing coatings meeting the needs for processing the most difficult-to-cut materials at the most extreme cutting conditions. The emerging of new workpiece, tool and film materials, the evolution of sophisticated coatings’ characterization methods and the continuous need for higher productivity rates, maintain vivid the industrial and scientific interest for further advancing this field.

Cutting with coated tools: Coating technologies, characterization methods and performance optimization

In the present contribution, numerical and experimental methodologies concerning orthogonal cutting are proposed in order to study the dry cutting of an aeronautic aluminium alloy (A2024-T351) The global aim concerns the comprehension of physical phenomena accompanying chip formation according to cutting velocity variation For the numerical model, material behaviour and its failure criterion are based on the Johnson–Cook law The model proposes a coupling between material damage evolution and its fracture energy A high-speed camera was used to capture the chip formation sequences The numerical results show that the chip–workpiece contact and the tool advancement induce bending loads on the chip Consequently, a fragmentation phenomenon takes place above the rake face when the chip begins to curl up The computed results corroborate with experimental ones The numerical results predict the residual stress distribution and show high values, along the cutting direction, on the machined workpiece surface

Numerical and experimental study of dry cutting for an aeronautic aluminium alloy (A2024-T351)

Ti1−xAlxN films and/or their alloys are employed in many industrial applications due to their excellent mechanical and thermal properties. Synthesized by plasma-assisted vapor deposition, Ti1−xAlxN is reported to crystallize in the cubic NaCl (c) structure for AlN mole fractions below 0.4–0.91, whereas at larger Al contents the hexagonal ZnS-wurtzite (w) structure is observed. Here we use ab initio calculations to analyze the effect of composition and Al distribution on the metal sublattice on phase stability, structure, and elastic properties of c-Ti1−xAlxN and w-Ti1−xAlxN. We show that the phase stability of supersaturated c-Ti1−xAlxN not only depends on the chemical composition but also on the Al distribution of the metal sublattice. An increase of the metastable solubility limit of AlN in c-Ti1−xAlxN from 0.64 to 0.74 is obtained by decreasing the number of Ti–Al bonds. This can be understood by considering the Al distribution induced changes of the electronic structure, bond energy, and configuration...

Influence of the Al distribution on the structure, elastic properties, and phase stability of supersaturated Ti1- xAlxN

The use of aluminum alloys in manufacturing industry has increased significantly in recent years. This is because primarily to their ability to combine lightness and strength in a single material. Concomitant to this growth, the machining of aluminum alloys has enormously increased in volumetric proportions—so that the chip volume represents up to 80 % of the original volume of the machined material in certain segments of the industry, like aerospace. In this context, knowledge of the characteristics of machinability of aluminum alloys is essential to provide industry and researchers with information that allows them to make the right decisions when they come to machining this fantastic material. The purpose of this review is to compile relevant information about the characteristics of machinability of aluminum alloys into a single document.

Machining of aluminum alloys: a review

The current review aims to provide an overview on the research performed with vanadium containing nitride hard coatings. Such coatings were synthesised with the objective of reducing the friction at high temperature via self-adaptation of the coating while still providing a high level of wear resistance. The lubricating effect is based on the formation of vanadium oxides with weakly bonded lattice planes and low melting temperature. The review focuses on aspects regarding the synthesis, structure and properties of these coatings and also includes a discussion on possible future developments and further improvements of the coating design.

Vanadium containing self-adaptive low-friction hard coatings for high-temperature applications: A review

A 3 μm thick superlattice structured TiAlN/VN coating has been deposited by the steered cathodic arc/unbalanced magnetron sputtering technique. The coating has been tested in dry high-speed milling of aluminium alloys Al7010-T7651 and AlSi9Cu1 and the performance compared to that of the diamond-like carbon (DLC) coated, TiAlCrYN coated and uncoated tools. In milling the Al7010-T7651 alloy, TiAlN/VN and DLC coated tools showed comparable performance, outperforming TiAlCrYN coated and uncoated tools by a factor of 2.3 and 3.5, respectively. In the case of milling AlSi9Cu1, the DLC coatings failed to produce any lifetime improvement, TiAlCrYN showed ∼ 65% longer lifetime thus rendering TiAlN/VN as the best performing coating with 100% longer lifetime compared to that of the uncoated tools. The tests further showed that TiAlN/VN reduces the cutting forces and improves the surface finish. Scanning electron microscopy of the cutting edge carried out after the cutting tests showed that the TiAlN/VN coating significantly reduces metal transfer and built-up edge formation. © 2006 Elsevier B.V. All rights reserved.

TiAlN/VN superlattice structured PVD coatings: A new alternative in machining of aluminium alloys for aerospace and automotive components

Novel TiAlCN/VCN nanoscale multilayer PVD coatings deposited by the combined high-power impulse magnetron sputtering/unbalanced magnetron sputtering (HIPIMS/UBM) technology

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TiAlN/VN superlattice structured PVD coatings: A new alternative in machining of aluminium alloys for aerospace and automotive components

Novel TiAlCN/VCN nanoscale multilayer PVD coatings deposited by the combined high-power impulse magnetron sputtering/unbalanced magnetron sputtering (HIPIMS/UBM) technology