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Wear of a high cBN content PCBN cutting tool during hard milling of powder metallurgy cold work tool steels
Dalarna University, Falun, Sweden.
Linköping University, Department of Physics, Chemistry and Biology. Linköping University, The Institute of Technology. Dalarna University, Falun, Sweden.
Uddeholms AB, Hagfors, Sweden.
Seco Tools AB, Fagersta, Sweden.
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2015 (English)In: Wear, ISSN 0043-1648, E-ISSN 1873-2577, Vol. 332, 752-761 p.Article in journal (Refereed) Published
Abstract [en]

The wear characteristics of a high cBN content PCBN cutting tool during hard milling of two different hardened cold work tool steels have been evaluated. Post-cutting examination of the worn cutting inserts were performed using high resolution field emission gun scanning electron microscopy, energy dispersive X-ray spectroscopy, Auger electron spectroscopy and optical surface profilometry. Also, the machined work material surfaces and collected chips were characterized in order to evaluate the prevailing wear mechanisms.

The results show that both flank and crater wear is controlled by continuous wear due to tribochemical reactions, adhesive wear and mild abrasive wear. Besides, the cutting inserts show a tendency to micro chipping along the cutting edge especially at higher cutting speed. The latter mechanism was also found to be dependent on type of work material. High lateral resolution Auger electron spectroscopy of the crater region show that the worn surface is covered by a thin SixOy rich tribofilm with a thickness of 50-500 nm, the tribofilm being thicker on the binder phase regions. Also, the Co-rich regions of the binder phase seem to be more tribochemically affected by the prevailing contact conditions as compared with the Wrich regions of the binder phase and the cBN phase.

Place, publisher, year, edition, pages
Elsevier, 2015. Vol. 332, 752-761 p.
Keyword [en]
PCBN, Milling, Cold work tool steel, Wear mechanisms, Surface analysis, AES
National Category
Natural Sciences
Identifiers
URN: urn:nbn:se:liu:diva-102547DOI: 10.1016/j.wear.2015.01.073ISI: 000357438100014OAI: oai:DiVA.org:liu-102547DiVA: diva2:678969
Available from: 2013-12-13 Created: 2013-12-13 Last updated: 2017-12-06Bibliographically approved
In thesis
1. Wear of coated and uncoated PCBN cutting tool used in turning and milling
Open this publication in new window or tab >>Wear of coated and uncoated PCBN cutting tool used in turning and milling
2014 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

This licentiate thesis has the main focus on evaluation of the wear of coated and uncoated polycrystalline cubic boron nitride cutting tool used in cutting operations against hardened steel. And to exam the surface finish and integrity of the work material used. Harder work material, higher cutting speed and cost reductions result in the development of harder and more wear resistance cutting tools. Although PCBN cutting tools have been used in over 30 years, little work have been done on PVD coated PCBN cutting tools. Therefore hard turning and hard milling experiments with PVD coated and uncoated cutting tools have been performed and evaluated. The coatings used in the present study are TiSiN and TiAlN. The wear scar and surface integrity have been examined with help of several different characterization techniques, for example scanning electron microscopy and Auger electron spectroscopy.

 

The results showed that the PCBN cutting tools used displayed crater wear, flank wear and edge micro chipping. While the influence of the coating on the crater and flank wear was very small and the coating showed a high tendency to spalling. Scratch testing of coated PCBN showed that, the TiAlN coating resulted in major adhesive fractures. This displays the importance of understanding the effect of different types of lapping/grinding processes in the pre-treatment of hard and super hard substrate materials and the amount and type of damage that they can create. For the cutting tools used in turning, patches of a adhered layer, mainly consisting of FexOy were shown at both the crater and flank. And for the cutting tools used in milling a tribofilm consisting of SixOy covered the crater. A combination of tribochemical reactions, adhesive wear and mild abrasive wear is believed to control the flank and crater wear of the PCBN cutting tools. On a microscopic scale the difference phases of the PCBN cutting tool used in turning showed different wear characteristics. The machined surface of the work material showed a smooth surface with a Ra-value in the range of 100-200 nm for the turned surface and 100-150 nm for the milled surface. With increasing crater and flank wear in combination with edge chipping the machined surface becomes rougher and showed a higher Ra-value. For the cutting tools used in milling the tendency to micro edge chipping was significant higher when milling the tools steels showing a higher hard phase content and a lower heat conductivity resulting in higher mechanical and thermal stresses at the cutting edge.

Place, publisher, year, edition, pages
Linköping: Linköping University Electronic Press, 2014. 39 p.
Series
Linköping Studies in Science and Technology. Thesis, ISSN 0280-7971 ; 1634
Keyword
PCBN, PVD coating, Wear mechanisms, Tool wear, Metal cutting
National Category
Natural Sciences
Identifiers
urn:nbn:se:liu:diva-102551 (URN)10.3384/lic.diva-102551 (DOI)LIU-TEK-LIC-2013:68 (Local ID)978-91-7519-443-1 (ISBN)LIU-TEK-LIC-2013:68 (Archive number)LIU-TEK-LIC-2013:68 (OAI)
Presentation
2014-01-17, Högskolan i Dalarna, Borlänge, 13:15 (Swedish)
Opponent
Supervisors
Available from: 2013-12-13 Created: 2013-12-13 Last updated: 2015-06-01Bibliographically approved

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