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Performance of TiAlN-PVD coated carbide tools in milling AISI D2 hardened steels

Rafai, Noor Hakim and Lajis, Mohd Amri and Hosni, N. A. J. (2013) Performance of TiAlN-PVD coated carbide tools in milling AISI D2 hardened steels. In: International Conference on Production Engineering (ICPE2013), 30-31 May 2013, Tokyo, Japan.


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This paper investigated the performance of PVD-TiAlN coated carbide end mills in milling AISI D2 hardened steels with a hardness value of HRC 58-62.The effect of cutting speeds on the tool wear, tool life and surface finish of machined workpiece were examined. Cutting tests were performed with constant depth of cut (0.5mm) and feed rate(0.05mm/tooth), and at various cutting speeds (80, 100 and 120 m/min) and radial depth of cuts (3, 4 and 5 mm) to investigate the performance of the insert under dry cutting condition. The PVD TiAlN coated carbide insert performs satisfactory under the conditions tested, as reasonable tool life is recorded. By relating the machining tests and tool life curves, the wear behavior of the coated insert was described. It is observed that wear of the tool mainly occurred on the flank wear. Detail studies revealed that the workpiece tends to adhere onto the rake face without any severe crater wear. Abrasion still occurred although TiAlN coatings are known to have high resistance to abrasive and crater wear due to their higher hot hardness and oxidation resistance. The findings are significant because previously only ceramic and cubic boron nitride (CBN) inserts are successfully used for machining. The lower cost of TiAlN coated tungsten carbide can result in significant economic savings. From the result it showed that tool life and the volume of material removal decreased as cutting speed and radial depth of cut increased due to higher temperature and contact area, respectively. The highest tool life recorded for TiAlN-PVD coated endmills was 9.68657 min and volume material removal (VMR) was 462.5 mm3 for 1850 mm of length of cut at the lowest cutting speed of 80 m/min, radial depth of cut of 3mm and feed of 0.05 mm/tooth.

Item Type: Conference or Workshop Item (Paper)
Uncontrolled Keywords: PVD-TiAlN coated carbide; machining; wear mechanisms; tool life; endmills; AISI D2 hardened steel; cutting performance
Subjects: T Technology > TJ Mechanical engineering and machinery > TJ1125-1345 Machine shops and machine shop practice
Divisions: Faculty of Mechanical and Manufacturing Engineering > Department of Manufacturing and Industrial Engineering
Depositing User: Normajihan Abd. Rahman
Date Deposited: 19 Jul 2013 02:38
Last Modified: 19 Jul 2013 02:38
URI: http://eprints.uthm.edu.my/id/eprint/4042
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