Duplex stainless steels (DSS) are preferred replacement to austenitic stainless steel because of their higher strength leading to economic benefits. However, poor ductility and thermal conductivity along with high toughness make them difficult to machine. In the present investigation, tool wear, cutting force and surface roughness were evaluated during dry turning of DSS 2205 using tungsten carbide inserts coated with AlTiCrN and AlTiN. High Power Impulse Magnetron Sputtering technique was used for coating the substrates. Cutting speeds of 100, 140 and 180 m/min; feed of 0.12, 0.15, and 0.18 mm/rev, and a fixed depth of cut of 0.8 mm were chosen as cutting parameters for dry turning. AlTiCrN coating exhibited highest adhesion strength of 110 N compared to 89 N by AlTiN coating. AlTiCrN coated tools exhibited highest tool life of 7840 mm, with least surface roughness of 0.72 µm and cutting force of 255 N. This is attributed to its excellent physical properties such as good adhesion, higher oxidation resistance and thermal stability, compared to AlTiN coated tool. AlTiCrN and AlTiN coated tools exhibited respectively 6-times and 4-times more tool life than uncoated tools. Combination of high speed (180 m/min) and low feed (0.12 mm/rev) resulted in least surface finish. Regression model developed from the experimental data showed closer agreement (95%) between predicted and experimental values of surface roughness.

Machinability Study of Duplex Stainless Steel 2205 During Dry Turning

In this article, the comprehensive review on the application, and indeed, a comparative analysis on dry machining of different types of materials (Inconel, steel, aluminum, cast iron, magnesium and advanced materials) used in machining (turning, drilling and milling operations) were carried out in the light of utmost works published in the literature. The work describes the scientific findings of the past twenty years, including sustainable methods (surface texture, solid lubricants, vibration-assisted machining, laser-assisted machining), tool coatings, and geometry of tools. Vibration-assisted machining is another direction that researchers have investigated without the use of cutting coolants, where the complete disposal of coolants is not possible. Various researchers have carried out rigorous experimental work on milling, drilling, and turning operations under dry conditions to machine numerous materials. A significant proportion of experimental data about tool wear, tool wear machining, surface quality, surface integrity, etc, has been analyzed under dry conditions. However, the critical analysis of dry machining for different conventional machining operations for a variety of industrial materials is still lacking for establishing dry machining as a sustainable process for industrial applications. Thus, the critical analysis of various machining parameters and their consequences on tool wear and the surface quality of machined work was carried out in this work. Finally, scientific recommendations based on critical findings were proposed for industrial implementation of dry machining.

https://iopscience.iop.org/article/10.1088/2053-1591/ac6fba/pdf

State of the art review on the sustainable dry machining of advanced materials for multifaceted engineering applications: progressive advancements and directions for future prospects

This study focuses on a comparative analysis of AlCrXN (X = Mo or V) coatings with the reference AlCrN coating via arc ion plating technique (AIP). The XRD and XPS results showed that the AlCrXN coatings were mainly composed of fcc-(Cr,Al)N solid solution phases. Both the AlCrMoN and AlCrVN coatings exhibited much higher hardness and adhesive strength than the AlCrN coating. The addition of Mo or V decreased the coefficient of friction (COF) and wear rate, which was due to the formation of lubricant oxides containing Mo or V on the coating surfaces. The cutting results showed that abrasive wear, adhesive wear, and oxidation wear were the main wear mechanisms for the coated tools at the cutting speeds of 60 m/min and 94 m/min. The addition of Mo or V dramatically improved the cutting performance of AlCrXN-coated tools by increasing the anti-wear ability due to the high hardness and the formed lubricant VOx or MoOx films.

Effect of Addition of Mo or V on the Structure and Cutting Performance of AlCrN-Based Coatings

In this study tool wear during CFRP milling is experimentally investigated to explore the optimization of various cutting condition. From the test machining, it was found that CFRP milling was conducted mostly through the brittle mode machining that creates chip with powder shape. Tool wear is originated from the flank wear generated by the friction force between flank face and machined surface as well as the cutting edge wear by an impact force of fiber cutting. The flank wear is focused on a fiber orientation as well as a friction distance of the flank face in this paper. Based on the results, the tool wear progression model is suggested considering the fiber orientation and the radial depth of cut. From the results, it was found that the fiber orientation greatly affects the flank wear which arises most severely at the parallel to the tool feed direction that induces larger friction force. Also, the radial depth of cut smaller than 10% of diametric engagement accelerates the flank wear due to the increase of friction distance. Using this correlation among parameters, wear prediction model with force equations was derived and estimation results sufficiently match with the wear measurement values.

Effect of the Fiber Orientation and the Radial Depth of Cut on the Flank Wear in End Milling of CFRP

Investigation of wear mechanisms of multilayer nanostructured wear-resistant coatings during turning of steel. Part 2: Diffusion, oxidation processes and cracking in Ti-TiN-(Ti,Cr,Mo,Al)N coating

Physical vapour deposition technique was used to deposit TiAlCrN coatings on the YT15 tungsten carbide inserts. The dry turning tests of 20CrMo steel were carried out to evaluate performances of TiAlCrN coated and uncoated tools on the CA6140A lathe. The effect of the two kinds of tools on cutting forces, cutting temperature, surface roughness and tool wear had been investigated to assess the performance of TiAlCrN coated tools. The results showed that the cutting force and cutting temperature obtained by TiAlCrN coated tools were decreased and the TiACrN coated tools produced a better surface finish in comparison with the uncoated tools. The TiAlCrN coated tools yield working life about 45 min, which was two times of that for uncoated tools. The wear mechanisms of the TiAlCrN coated tools were mainly oxidation and boundary wear, accompanied with diffusion wear.

Research on the Cutting Performances and Wear Mechanisms of TiAlCrN Coated Tools During Dry Turning

AlCrN and TiAlSiN coatings were deposited on the surface of 30CrMnSi steel and cemented carbide YT15 by multi-arc ion plating technique. A scanning electron microscopy was used to observe the surface morphologies of both coatings. The reciprocating sliding tests of AlCrN and TiAlSiN coating were performed to investigate the friction coefficients and the wear mechanisms of both coatings were analyzed as well. Dry machining tests on 30CrMnSi hardened steel were carried out with the AlCrN and TiAlSiN coated tools on a CA6140A lathe. The effects of cutting speed on cutting forces and cutting temperatures of AlCrN and TiAlSiN coated tools were obtained and analyzed. The microcosmic micrographs of wear areas of both coated tools were observed and investigated by scanning electron microscope and energy dispersive spectrum. The results show that the hardness and bonding strength of AlCrN coating are higher than that of TiAlSiN coating, while the friction coefficient of AlCrN coating is lower than that of TiAlSiN coating. Both the cutting force and cutting temperature of AlCrN coated tool are lower than TiAlSiN coated tool. The time required for the bluntness of the AlCrN coated tool is approximately 33.3% longer than that of the TiAlSiN coated tool, and the main wear mechanisms of both tools are mainly crater wear, diffusion wear and oxidation wear.

Research on Friction Characteristics of AlCrN and TiAlSiN Coatings and Properties of Coated Tools

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Research on the Cutting Performances and Wear Mechanisms of TiAlCrN Coated Tools During Dry Turning

Research on Friction Characteristics of AlCrN and TiAlSiN Coatings and Properties of Coated Tools

Waxing device for plate -shaped workpiece