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Saroj Kuma Patel - One of the best experts on this subject based on the ideXlab platform.

  • applicability of dlc and wc c low friction coatings on al2o3 ticn mixed Ceramic Cutting Tools for dry machining of hardened 52100 steel
    Ceramics International, 2020
    Co-Authors: Ch Sateesh Kuma, Himadri Majumde, Akhta Kha, Saroj Kuma Patel
    Abstract:

    Abstract The present work examines the applicability of DLC and WC/C low friction coatings on Al2O3/TiCN based mixed Ceramic Cutting Tools for the dry and hard turning of AISI 52100 steel (62 HRC). The characterization of coated Tools reveals that the coatings retain very low values of surface roughness, whereas the DLC coating exhibits much higher microhardness when compared to the WC/C coating. On the other hand, the WC/C coating exhibit a coarse surface morphology virtually due to the tungsten doping. Later, continuous turning tests were executed with the help of coated and uncoated Cutting Tools under dry Cutting conditions, and their performance was investigated in terms of machining forces, Cutting temperature and tool wear. Coating delamination by flaking and peeling is quite prominent in the case of both the coatings; however, it is less severe for the WC/C coated tool. The coatings help to reduce machining forces, Cutting temperatures and tool wear, but the performance of coated Tools converge towards uncoated tool as the Cutting speed, and feed rate is increased. Both the coatings prevent the development of cracks near the Cutting edge with WC/C coating exhibiting superior wear behavior basically due to its multilayered structure and better thermal stability. Moreover, the tested low friction coatings don't serve as thermal barriers and only the lubrication generated due to graphitization at the chip-tool interface is mostly responsible for the improved machining performance.

  • effect of duplex nanostructured tialsin tisin tialn tialn and tialn tialsin tisin tialn coatings on the hard turning performance of al2o3 ticn Ceramic Cutting Tools
    Wear, 2019
    Co-Authors: Ch Sateesh Kuma, Saroj Kuma Patel
    Abstract:

    Abstract The present work explores the hard turning performance of nanostructured TiAlSiN/TiSiN/TiAlN-TiAlN and TiAlN-TiAlSiN/TiSiN/TiAlN duplex coatings on Al2O3-TiCN Ceramic Cutting Tools. The performance of these coatings has been compared with that of uncoated and TiAlSiN/TiSiN/TiAlN coated Cutting Tools. The deposition of coatings in duplex form resulted in increase of coating thickness that caused increase in compressive residual stress which in turn resulted in chipping wear during the turning tests. Further, a thick TiAlN layer on the Ceramic substrate resulted in significant decrease of coating/substrate adhesion strength. TiAlSiN/TiSiN/TiAlN nanocomposite coating outperformed duplex coatings under each condition due to lower thin film thickness and better coating/substrate adhesion strength. The TiAlSiN layer exhibited superior anti-adhesive and anti-abrasive behaviour when compared to TiAlN layer.

  • effect of wedm surface texturing on al2o3 ticn composite Ceramic Tools in dry Cutting of hardened steel
    Ceramics International, 2018
    Co-Authors: Ch Sateesh Kuma, Saroj Kuma Patel
    Abstract:

    Abstract Micro scale textures were fabricated on the rake surface of Al2O3/TiCN composite Ceramic Cutting Tools using WEDM process. The Cutting performance of Ceramic Cutting Tools with plain and textured rake surfaces was investigated in the dry Cutting of hardened AISI 52100 steel (62 HRC). The performance of Cutting Tools was evaluated by chip-tool contact length, tool wear, machining forces, Cutting temperature, frictional coefficient and chip morphology. Further, a 3D finite element model has been used to study the temperature and stress distribution in the Cutting Tools. Application of textures obstructing the chip flow direction resulted in uniform stress distribution, and higher groove sliding area ensured maximum reduction of machining forces, material adhesion, Cutting and tool temperature. However, the textures parallel to the chip flow direction resulted in bending and curling of chips on the rake face causing an increase of chip-tool contact length and material adhesion as compared to the Tools with textures obstructing the chip flow resulting in an increase of friction. The textured tool with textures inclined at an angle to the chip flow direction exhibited the best machining performance as compared to other textured Cutting Tools. Moreover, this tool exhibited superior anti-adhesion behavior as compared to the conventional Cutting tool owing to the reduced chip-tool contact length and area, friction and chip flow angle.

Youqiang Xing - One of the best experts on this subject based on the ideXlab platform.

  • fabrication and dry Cutting performance of si3n4 tic Ceramic Tools reinforced with the pvd ws2 zr soft coatings
    Ceramics International, 2015
    Co-Authors: Youqiang Xing, Jianxi Deng, Kedong Zhang, Xingsheng Wang, Yunsong Lia, Yonghui Zhou
    Abstract:

    Abstract WS 2 /Zr soft-coatings were deposited on Si 3 N 4 /TiC Ceramic Cutting Tools by medium-frequency magnetron sputtering together with multi-arc ion plating. Microstructural and fundamental properties of the coatings were examined and dry Cutting tests on hardened steel were carried out. The Cutting performance and wear characteristic of the coated Tools were investigated compared with uncoated tool. Results show that the WS 2 /Zr coated Si 3 N 4 /TiC Cutting Tools significantly improve the lubricity at the tool–chip interface; the Cutting force, Cutting temperature, friction coefficient and tool wear are reduced and the tool life is increased compared with uncoated tool. Crater wear and flank wear occurred both on uncoated and coated Tools. Abrasive wear, adhesions and chipping are the predominant wear mechanisms of uncoated tool on crater wear and flank wear; abrasive wear, coating delamination and chipping are the main wear mechanisms of WS 2 /Zr coated Tools. Friction-reduction and increased wear-resistance are attributed to the formation of a transfer lubricant layer at the tool–chip interface during the dry Cutting process.

  • Cutting performance and wear characteristics of al2o3 tic Ceramic Cutting Tools with ws2 zr soft coatings and nano textures in dry Cutting
    Wear, 2014
    Co-Authors: Youqiang Xing, Jianxi Deng, Hongzhi Yue, Rong Meng, Peng Gao
    Abstract:

    Abstract To improve the Cutting performance and reduce the tool wear, novel Al2O3/TiC Cutting Tools were developed with coating and laser technologies: first, the WS2/Zr coated Al2O3/TiC Ceramic Cutting tool; second, nano-textured Al2O3/TiC Ceramic Cutting Tools deposited with WS2/Zr composite soft-coatings. Dry Cutting tests were carried out on hardened steel with the conventional and developed Tools. The Cutting force, Cutting temperature, friction coefficient, and tool wear were measured. Results show that the WS2/Zr coated Al2O3/TiC Cutting Tools with and without nano-textures significantly improve the lubricity at the tool-chip interface; the Cutting force, Cutting temperature, friction coefficient and tool wear are reduced compared with the conventional Tools; the nano-textured Tools deposited with WS2/Zr composite soft-coatings are the most effective. In addition, the geometry of nano-textures has a profound effect on the lubricity, the WS2/Zr coated Cutting tool with areal nano-textures is the most effective in improving the Cutting performance and reducing the tool wear. The abrasive wear, chipping and adhesions are the predominant wear characteristics of conventional Tools, the abrasive wear and coating flaking is for coated Tools, and the adhesions at the tool tip is mainly for the coated Tools with nano-textures.

  • effect of femtosecond laser pretreatment on wear resistance of al2o3 tic Ceramic Tools in dry Cutting
    International Journal of Refractory Metals & Hard Materials, 2014
    Co-Authors: Youqiang Xing, Jianxi Deng, Kedong Zhang, Guodong Zhang, Huanhua Gao
    Abstract:

    Abstract A femtosecond pulsed laser (pulse width: 120 fs, wavelength: 800 nm and repetition rate: 500 Hz) was used for the pretreatment on the rake face of Al 2 O 3 /TiC Ceramic Cutting Tools. The evolution of surface morphology of pretreated Cutting Tools irradiated with different pulse energies was measured by scanning electron microscope (SEM) and atomic force microscope (AFM). Dry Cutting tests were carried out with these pretreated Tools and conventional Tools on hardened steel. The effect of pulse energy on the wear resistance of these pretreated Tools was investigated. Results show that the Cutting forces have no significant difference between laser pretreated Tools and the conventional tool; the Cutting temperatures of laser pretreated Tools were slightly reduced compared with the conventional tool. Meanwhile, we found that the laser pretreated Tools increased the adhesions of chips on the rake face, but they can significantly improve the wear resistance of the rake face; and laser pulse energy was found to have a profound effect on the wear resistance of the laser pretreated Tools.

Ch Sateesh Kuma - One of the best experts on this subject based on the ideXlab platform.

  • applicability of dlc and wc c low friction coatings on al2o3 ticn mixed Ceramic Cutting Tools for dry machining of hardened 52100 steel
    Ceramics International, 2020
    Co-Authors: Ch Sateesh Kuma, Himadri Majumde, Akhta Kha, Saroj Kuma Patel
    Abstract:

    Abstract The present work examines the applicability of DLC and WC/C low friction coatings on Al2O3/TiCN based mixed Ceramic Cutting Tools for the dry and hard turning of AISI 52100 steel (62 HRC). The characterization of coated Tools reveals that the coatings retain very low values of surface roughness, whereas the DLC coating exhibits much higher microhardness when compared to the WC/C coating. On the other hand, the WC/C coating exhibit a coarse surface morphology virtually due to the tungsten doping. Later, continuous turning tests were executed with the help of coated and uncoated Cutting Tools under dry Cutting conditions, and their performance was investigated in terms of machining forces, Cutting temperature and tool wear. Coating delamination by flaking and peeling is quite prominent in the case of both the coatings; however, it is less severe for the WC/C coated tool. The coatings help to reduce machining forces, Cutting temperatures and tool wear, but the performance of coated Tools converge towards uncoated tool as the Cutting speed, and feed rate is increased. Both the coatings prevent the development of cracks near the Cutting edge with WC/C coating exhibiting superior wear behavior basically due to its multilayered structure and better thermal stability. Moreover, the tested low friction coatings don't serve as thermal barriers and only the lubrication generated due to graphitization at the chip-tool interface is mostly responsible for the improved machining performance.

  • effect of duplex nanostructured tialsin tisin tialn tialn and tialn tialsin tisin tialn coatings on the hard turning performance of al2o3 ticn Ceramic Cutting Tools
    Wear, 2019
    Co-Authors: Ch Sateesh Kuma, Saroj Kuma Patel
    Abstract:

    Abstract The present work explores the hard turning performance of nanostructured TiAlSiN/TiSiN/TiAlN-TiAlN and TiAlN-TiAlSiN/TiSiN/TiAlN duplex coatings on Al2O3-TiCN Ceramic Cutting Tools. The performance of these coatings has been compared with that of uncoated and TiAlSiN/TiSiN/TiAlN coated Cutting Tools. The deposition of coatings in duplex form resulted in increase of coating thickness that caused increase in compressive residual stress which in turn resulted in chipping wear during the turning tests. Further, a thick TiAlN layer on the Ceramic substrate resulted in significant decrease of coating/substrate adhesion strength. TiAlSiN/TiSiN/TiAlN nanocomposite coating outperformed duplex coatings under each condition due to lower thin film thickness and better coating/substrate adhesion strength. The TiAlSiN layer exhibited superior anti-adhesive and anti-abrasive behaviour when compared to TiAlN layer.

  • effect of wedm surface texturing on al2o3 ticn composite Ceramic Tools in dry Cutting of hardened steel
    Ceramics International, 2018
    Co-Authors: Ch Sateesh Kuma, Saroj Kuma Patel
    Abstract:

    Abstract Micro scale textures were fabricated on the rake surface of Al2O3/TiCN composite Ceramic Cutting Tools using WEDM process. The Cutting performance of Ceramic Cutting Tools with plain and textured rake surfaces was investigated in the dry Cutting of hardened AISI 52100 steel (62 HRC). The performance of Cutting Tools was evaluated by chip-tool contact length, tool wear, machining forces, Cutting temperature, frictional coefficient and chip morphology. Further, a 3D finite element model has been used to study the temperature and stress distribution in the Cutting Tools. Application of textures obstructing the chip flow direction resulted in uniform stress distribution, and higher groove sliding area ensured maximum reduction of machining forces, material adhesion, Cutting and tool temperature. However, the textures parallel to the chip flow direction resulted in bending and curling of chips on the rake face causing an increase of chip-tool contact length and material adhesion as compared to the Tools with textures obstructing the chip flow resulting in an increase of friction. The textured tool with textures inclined at an angle to the chip flow direction exhibited the best machining performance as compared to other textured Cutting Tools. Moreover, this tool exhibited superior anti-adhesion behavior as compared to the conventional Cutting tool owing to the reduced chip-tool contact length and area, friction and chip flow angle.

Jianxi Deng - One of the best experts on this subject based on the ideXlab platform.

  • fabrication and dry Cutting performance of si3n4 tic Ceramic Tools reinforced with the pvd ws2 zr soft coatings
    Ceramics International, 2015
    Co-Authors: Youqiang Xing, Jianxi Deng, Kedong Zhang, Xingsheng Wang, Yunsong Lia, Yonghui Zhou
    Abstract:

    Abstract WS 2 /Zr soft-coatings were deposited on Si 3 N 4 /TiC Ceramic Cutting Tools by medium-frequency magnetron sputtering together with multi-arc ion plating. Microstructural and fundamental properties of the coatings were examined and dry Cutting tests on hardened steel were carried out. The Cutting performance and wear characteristic of the coated Tools were investigated compared with uncoated tool. Results show that the WS 2 /Zr coated Si 3 N 4 /TiC Cutting Tools significantly improve the lubricity at the tool–chip interface; the Cutting force, Cutting temperature, friction coefficient and tool wear are reduced and the tool life is increased compared with uncoated tool. Crater wear and flank wear occurred both on uncoated and coated Tools. Abrasive wear, adhesions and chipping are the predominant wear mechanisms of uncoated tool on crater wear and flank wear; abrasive wear, coating delamination and chipping are the main wear mechanisms of WS 2 /Zr coated Tools. Friction-reduction and increased wear-resistance are attributed to the formation of a transfer lubricant layer at the tool–chip interface during the dry Cutting process.

  • Cutting performance and wear characteristics of al2o3 tic Ceramic Cutting Tools with ws2 zr soft coatings and nano textures in dry Cutting
    Wear, 2014
    Co-Authors: Youqiang Xing, Jianxi Deng, Hongzhi Yue, Rong Meng, Peng Gao
    Abstract:

    Abstract To improve the Cutting performance and reduce the tool wear, novel Al2O3/TiC Cutting Tools were developed with coating and laser technologies: first, the WS2/Zr coated Al2O3/TiC Ceramic Cutting tool; second, nano-textured Al2O3/TiC Ceramic Cutting Tools deposited with WS2/Zr composite soft-coatings. Dry Cutting tests were carried out on hardened steel with the conventional and developed Tools. The Cutting force, Cutting temperature, friction coefficient, and tool wear were measured. Results show that the WS2/Zr coated Al2O3/TiC Cutting Tools with and without nano-textures significantly improve the lubricity at the tool-chip interface; the Cutting force, Cutting temperature, friction coefficient and tool wear are reduced compared with the conventional Tools; the nano-textured Tools deposited with WS2/Zr composite soft-coatings are the most effective. In addition, the geometry of nano-textures has a profound effect on the lubricity, the WS2/Zr coated Cutting tool with areal nano-textures is the most effective in improving the Cutting performance and reducing the tool wear. The abrasive wear, chipping and adhesions are the predominant wear characteristics of conventional Tools, the abrasive wear and coating flaking is for coated Tools, and the adhesions at the tool tip is mainly for the coated Tools with nano-textures.

  • effect of femtosecond laser pretreatment on wear resistance of al2o3 tic Ceramic Tools in dry Cutting
    International Journal of Refractory Metals & Hard Materials, 2014
    Co-Authors: Youqiang Xing, Jianxi Deng, Kedong Zhang, Guodong Zhang, Huanhua Gao
    Abstract:

    Abstract A femtosecond pulsed laser (pulse width: 120 fs, wavelength: 800 nm and repetition rate: 500 Hz) was used for the pretreatment on the rake face of Al 2 O 3 /TiC Ceramic Cutting Tools. The evolution of surface morphology of pretreated Cutting Tools irradiated with different pulse energies was measured by scanning electron microscope (SEM) and atomic force microscope (AFM). Dry Cutting tests were carried out with these pretreated Tools and conventional Tools on hardened steel. The effect of pulse energy on the wear resistance of these pretreated Tools was investigated. Results show that the Cutting forces have no significant difference between laser pretreated Tools and the conventional tool; the Cutting temperatures of laser pretreated Tools were slightly reduced compared with the conventional tool. Meanwhile, we found that the laser pretreated Tools increased the adhesions of chips on the rake face, but they can significantly improve the wear resistance of the rake face; and laser pulse energy was found to have a profound effect on the wear resistance of the laser pretreated Tools.

Peng Gao - One of the best experts on this subject based on the ideXlab platform.

  • Cutting performance and wear characteristics of al2o3 tic Ceramic Cutting Tools with ws2 zr soft coatings and nano textures in dry Cutting
    Wear, 2014
    Co-Authors: Youqiang Xing, Jianxi Deng, Hongzhi Yue, Rong Meng, Peng Gao
    Abstract:

    Abstract To improve the Cutting performance and reduce the tool wear, novel Al2O3/TiC Cutting Tools were developed with coating and laser technologies: first, the WS2/Zr coated Al2O3/TiC Ceramic Cutting tool; second, nano-textured Al2O3/TiC Ceramic Cutting Tools deposited with WS2/Zr composite soft-coatings. Dry Cutting tests were carried out on hardened steel with the conventional and developed Tools. The Cutting force, Cutting temperature, friction coefficient, and tool wear were measured. Results show that the WS2/Zr coated Al2O3/TiC Cutting Tools with and without nano-textures significantly improve the lubricity at the tool-chip interface; the Cutting force, Cutting temperature, friction coefficient and tool wear are reduced compared with the conventional Tools; the nano-textured Tools deposited with WS2/Zr composite soft-coatings are the most effective. In addition, the geometry of nano-textures has a profound effect on the lubricity, the WS2/Zr coated Cutting tool with areal nano-textures is the most effective in improving the Cutting performance and reducing the tool wear. The abrasive wear, chipping and adhesions are the predominant wear characteristics of conventional Tools, the abrasive wear and coating flaking is for coated Tools, and the adhesions at the tool tip is mainly for the coated Tools with nano-textures.