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

Yıl 2018, Cilt: 4 Sayı: 2, 189 - 211, 31.12.2018

Sadettin Cem Altıparmak

Öz

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.

Anahtar Kelimeler

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

Öz

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.

Anahtar Kelimeler

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

Kaynakça

• [1] M. Staszuk, D. Pakuła, G. Chladek, M. Pawlyta, M. Pancielejko, and P. Czaja, “Investigation of the structure and properties of PVD coatings and ALD + PVD hybrid coatings deposited on sialon tool ceramics,” Vacuum, vol. 154, no. March, pp. 272–284, 2018.
• [2] K. Aslantas, T. I. Ucun, and A. çicek, “Tool life and wear mechanism of coated and uncoated Al2O3/TiCN mixed ceramic tools in turning hardened alloy steel,” Wear, vol. 274–275, no. February 2018, pp. 442–451, 2012.
• [3] D. Dudzinski, A. Devillez, A.Moufki, D. Larrouquere, V. Zerrouki, and J. Vigneau, “A Review of Developments Towards Dry and High Speed Machining of Inconel 718 Alloy,” Int. J. of Machine Tools & Manufacture, Vol.44, pp. 439-456, 2004.
• [4] G. S. Goindi and P. Sarkar, “Dry machining: A step towards sustainable machining–Challenges and future directions,” J. Clean. Prod., vol. 165, pp. 1557–1571, 2017.
• [5] M. Fahad, P. T. Mativenga, and M. a. Sheikh, “Critical design factors for multi-layer coating systems that influence heat partition in the secondary shear deformation zone and machining performance,” Proc. Inst. Mech. Eng. Part B J. Eng. Manuf., vol. 226, no.6, pp. 1071–1085, 2012.
• [6] A. Hosokawa, K. Shimamura, and T. Ueda, “Cutting characteristics of PVD-coated tools deposited by Unbalanced Magnetron Sputtering method,” CIRP Ann. - Manuf. Technol., vol. 61, no. 1, pp. 95–98, 2012.
• [7] X. Zhang, R. Huang, K. Liu, A. S. Kumar, and X. Shan, “Rotating-tool diamond turning of Fresnel lenses on a roller mold for manufacturing of functional optical film,” Precis. Eng., vol. 51, no. July 2017, pp. 445–457, 2018.
• [8] H. Schulz and T. Moriwaki, “High-speed Machining,” CIRP Ann. - Manuf. Technol., vol. 41, no. 2, pp. 637–643, 1992.
• [9] P. Fallböhmer, C. A. Rodríguez, T. Özel, and T. Altan, “High-speed machining of cast iron and alloy steels for die and mold manufacturing,” J. Mater. Process. Technol., vol. 98, no. 1, pp. 104–115, 2000.
• [10] Neugebauer, R., Bouzakis, K.-D., Denkena, B., Klocke, F., terzing, A., Tekkaya, A.E., Wertheim, R., Velocity Effects in Metal Forming and Machining Processes, Annals of CIRP Vol. 60/2, p. 627-650, 2011.
• [11] F. Klocke, T. Krieg, K. Gerschwiler, R. Fritsch, V. Zinkann, M. Pöhls, and G. Eisenblätter, “Improved Cutting Processes with Adapted Coating Systems,” CIRP Annals, vol. 47, no. 1, pp. 65–68, 1998.
• [12] K. D. Bouzakis, N. Michailidis, G. Skordaris, E. Bouzakis, D. Biermann, and R. M’Saoubi, “Cutting with coated tools: Coating technologies, characterization methods and performance optimization,” CIRP Ann. - Manuf. Technol., vol. 61, no. 2, pp. 703–723, 2012.
• [13] A. Devillez, F. Schneider, S. Dominiak, D. Dudzinski, and D. Larrouquere, “Cutting forces and wear in dry machining of Inconel 718 with coated carbide tools,” Wear, vol. 262, no. 7–8, pp. 931–942, 2007.
• [14] K. K. Gajrani, S. Suresh, and M. R. Sankar, “Environmental riendly hard machining performance of uncoated and MoS2coated mechanical micro-textured tungsten carbide cutting tools,” Tribol. Int., vol. 125, no. December 2017, pp. 141–155, 2018.
• [15] K. Aruna Prabha, B. Srinivasa Prasad, and N. Srilatha, “Comparative Study of Wear Patterns of both Coated and Uncoated Tool Inserts in High Speed Turning of EN36 Steel,” Mater. Today Proc., vol. 5, no. 2, pp. 4368–4375, 2018.
• [16] S. Kumar. T., R. Ramanujam, M. Vignesh, N. Tamiloli, N. Sharma, S. Srivastava and A. Patel, “Comparative evaluation of performances of TiAlN, AlCrN, TiAlN/AlCrN coated carbide cutting tools and uncoated carbide cutting tools on turning Inconel 825 alloy using Grey Relational Analysis,” Sensors Actuators, A Phys., vol. 279, pp. 331–342, 2018.
• [17] F. Qin, Y. K. Chou, D. Nolen, and R. G. Thompson, “Coatingthickness effects on diamond coated cutting tools,” Surf. Coatings Technol., vol. 204, no. 6–7, p p. 1056–1060, 2009.
• [18] L. Braginsky, A. Gusarov, and V. Shklover, “Models of thermal conductivity of multilayer wear resistant coatings,” Surf. Coatings Technol., vol. 204, no. 5, pp. 629–634, 2009.
• [19] N. Abukhshim, P. Mativenga, and M. Sheikh, “Heat generation and temperature prediction in metal cutting: A review and implications for high speed machining,” International Journal of Machine Tools and Manufacture, vol. 46, no. 7-8, pp. 782–800, 2006.
• [20] N. R. CHRISTIE, “Fundamentals of Machining and Machine Tools (2nd edition). By GEOFFREY BOOTHROYD and W. A. KNIGHT (Marcel Dekker, Inc., 1989.),” Int. J. Prod. Res., vol. 28, no. 1, pp. 215–215, 1990.
• [21] Akbar, F., Mativenga, P. T. and Sheikh, M. A. ‘An evaluation of heat partition in the high-speed turning of AISI/SAE 4140 steel with uncoated and TiN-coated tools’, Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 222(7), pp. 759–771, 2008.
• [22] P.H. Mayrhofer, C. Mitterer 'High-temperature properties of nanocomposite TiBxNy and TiBxCy coatings, Surf. Coat. Technol', 133-134, pp. 131–137, 2000.
• [23] R. Daniel, D. Holec, M. Bartosik, J. Keckes, C. Mitterer, 'Size effect of thermal expansion and thermal/intrinsic stresses in nanostructured thin films: experiment and model', Acta Mater. 59, pp. 6631–6645, 2011.
• [24] R. Daniel, K.J. Martinschitz, J. Keckes, C. Mitterer, 'The origin of stresses in magnetron-sputtered thin films with zone T structures', Acta Mater. 58, pp. 2621–2633, 2010.
• [25] P.H.Mayrhofer, C. Mitterer, J.Musil 'Structure–property relationships in single-and dual-phase nanocrystalline hard coatings', Surf. Coat. Technol. 174-175, pp. 725–731, 2003.
• [26] Vereschaka, A. A. ‘Delamination and longitudinal cracking in multi-layered composite nano-structured coatings and their influence on cutting tool life’, Wear. Elsevier B.V., wear.2017.07.021, 390–391(July), pp. 209–219, 2017.
• [27] Fahad, M., Mativenga, P. T. and Sheikh, M. A., ‘An nvestigation of multilayer coated (TiCN/Al2O3-TiN) tungsten carbide tools in high speed cutting using a hybrid finite element and experimental technique’, Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 225(10), pp. 1835–1850, 2011.
• [28] Krajinovic, I., Daves, W., Tkadletz, M., Teppernegg, T., Klünsner, T., Schalk, N., … Czettl, C., Finite element study of the influence of hard coatings on hard metal tool loading during milling. Surface and Coatings Technology, 304, 134-141, 2016.
• [29] Bartosik, M., Holec, D., Apel, D., Klaus, M., Genzel, C., Keckes, J., … Mayrhofer, P. H., Thermal expansion of Ti-Al-N and Cr-Al-N coatings. Scripta Materialia, 127, 182-185, 2017.
• [30] Klocke, F. and Krieg, T., ‘Coated tools for metal cutting - features and applications’, CIRP Annals - Manufacturing Technology, 48(2), pp. 515–525, 1999.
• [31] Kumar, M. P., ‘Study on Tool Life and its Failure Mechanisms’, 2(04), pp. 126–131, 2015.
• [32] B. Prakash, J.Mukerji, S.Kalia, 'Tribological properties of Al2O3/TiN composites', Am. Ceram. Soc. Bull 77, pp. 68–72, 1998.