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

Year 2018, Volume: 4 Issue: 2, 189 - 211, 31.12.2018

Sadettin Cem Altıparmak

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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