ANALYSIS OF THERMAL EXPANSION AND MICRO-DELAMINATION PHENOMENON OF CUTTING TOOL THIN SURFACE COATINGS IN HIGH-SPEED DRY MACHINING

Abstract

ABSTRACT

High-speed machining (HSM) is one of the commonly implemented recent machining technologies in industrial manufacturing operations that enables higher efficiency and accuracy as reducing production cost and machining cycle times depending on the specific manufacturing operation requirements and demands. Particularly dry machining is characterised with severe level of temperature and heat generation enters into cutting tools rather than machining with cutting liquid, which leads to detrimental effects on tool lifespan resulting in premature cutting tool failure or tool damages. In order to overcome this problem, cutting tool thin surface coatings are applied to reduce the amount of heat transferring into cutting tool by enhancing the tribological conditions and wear resistance of cutting tools. However, as a result of the coefficient of thermal expansion (CTE) mismatching of coating layer materials, delamination phenomenon can be observed in coating structures during machining. As outcomes of the study based on the results obtained, total dimensional thermal expansion and micro-delamination of the most appropriate optimised 3-layered coating structure were relatively decreased and the necessity of the thermal expansion capacity consideration in coating implementations was revealed for related Finite Element Analysis (FEA) simulations and coating structure designs.

Keywords

• HSM technology; Multi-layer coatings; Delamination; Thermal expansion; CTE

ANALYSIS OF THERMAL EXPANSION AND MICRO-DELAMINATION PHENOMENON OF CUTTING TOOL THIN SURFACE COATINGS IN HIGH-SPEED DRY MACHINING

Abstract

ÖZET

Yüksek-hızlı kesim tekniği günümüzde sanayide yaygınca kullanılan bir metal kesme tekniğidir. Bu teknik üretimin verimliğini arttırırken imalat gereksinimlerine bağlı olarak işlem süresini ve maliyeti düşürür. Özellikle kuru kesim ıslak kesime nazaran, yüksek mertebelerdeki sıcaklık ve ısı oluşumuyla karakterize edilir. Oluşan bu ısının bir miktarı kesici takımın içerisine transfer olur ve bu ısı miktarı kesici takımın ömrünü azaltırken kesici takımda beklenenden erken hasarlara yol açar. Bu sorunun ortadan kaldırılmasıyla ilgili olarak transfer olan ısıyı ve kesici takımın yüzeyinin yenmesini azaltmak aynı zamanda kesici takımın sürtünme durumunu arttırmak için kesici takımlara ince yüzey kaplamaları uygulanır. Ancak metal kesme işlemi boyunca bu yüzey kaplama malzemelerinin termal genleşme değerlerinin farklılığından dolayı katman ayrışması olayı gözlemlenebilir. Buradan hareketle elde edilen sonuçlara dayanarak yapılan çalışmada, 3-katmanlı optimize edilmiş yüzey kaplaması ile 2-katmanlı ve tek-katmanlı kaplamalarla karşılaştırıldığında daha az miktarda toplam eksenel genleşme ve katman ayrışması elde edilmiştir. Ayrıca termal genleşme kapasitesi ve katman ayrışması olaylarının ilgili sonlu elemanlar analizlerinde ve çoklu yüzey kaplamaları dizaynlarında göz ardı edilmemesinin gerekliliği ortaya koyulmuştur.

Keywords

• Yüksek-hızlı kesim tekniği; Çoklu yüzey kaplamaları; Katman ayrışması; Termal genleşme; Termal genleşme katsayısı

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