Significance of Tool Coating Properties and Compacted Graphite Iron Microstructure for Tool Selection in Extreme Machining
This study aims to determine the extent to which coating composition and workpiece properties impact machinability and tool selection when turning Compacted Graphite Iron (CGI) under extreme roughing conditions. Two CGI workpieces, differing in pearlite content and graphite nodularity, were machined...
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MDPI AG
2025-01-01
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| Series: | Nanomaterials |
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| Online Access: | https://www.mdpi.com/2079-4991/15/2/130 |
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| author | Anna Maria Esposito Qianxi He Jose M. DePaiva Stephen C. Veldhuis |
| author_facet | Anna Maria Esposito Qianxi He Jose M. DePaiva Stephen C. Veldhuis |
| author_sort | Anna Maria Esposito |
| collection | DOAJ |
| description | This study aims to determine the extent to which coating composition and workpiece properties impact machinability and tool selection when turning Compacted Graphite Iron (CGI) under extreme roughing conditions. Two CGI workpieces, differing in pearlite content and graphite nodularity, were machined at a cutting speed of 180 m/min, feed rate of 0.18 mm/rev, and depth of cut of 3 mm. To assess the impact of tool properties across a wide range of commercially available tools, four diverse multilayered cemented carbide tools were evaluated: Tool A and Tool B with a thin AlTiSiN PVD coating, Tool C with a thick Al<sub>2</sub>O<sub>3</sub>-TiCN CVD coating, and Tool D with a thin Al<sub>2</sub>O<sub>3</sub>-TiC PVD coating. The machinability of CGI and wear mechanisms were analyzed using pre-cutting characterization, in-process optical microscopy, and post-test SEM analysis. The results revealed that CGI microstructural variations only affected tool life for Tool A, with a 110% increase in tool life between machining CGI Grade B and Grade A, but that the effects were negligible for all other tools. Tool C had a 250% and 70% longer tool life compared to the next best performance (Tool A) for CGI Grade A and CGI Grade B, respectively. With its thick CVD-coating, Tool C consistently outperformed the others due to its superior protection of the flank face and cutting edge under high-stress conditions. The cutting-induced stresses played a more significant role in the tool wear process than minor differences in workpiece microstructure or tool properties, and a thick CVD coating was most effective in addressing the tool wear effects for the extreme roughing conditions. However, differences in tool life for Tool A showed that tool behavior cannot be predicted based on a single system parameter, even for extreme conditions. Instead, tool properties, workpiece properties, cutting conditions, and their interactions should be considered collectively to evaluate the extent that an individual parameter impacts machinability. This research demonstrates that a comprehensive approach such as this can allow for more effective tool selection and thus lead to significant cost savings and more efficient manufacturing operations. |
| format | Article |
| id | doaj-art-18ad35bee3a84ffeb365bb34db79cfcf |
| institution | Kabale University |
| issn | 2079-4991 |
| language | English |
| publishDate | 2025-01-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Nanomaterials |
| spelling | doaj-art-18ad35bee3a84ffeb365bb34db79cfcf2025-01-24T13:44:15ZengMDPI AGNanomaterials2079-49912025-01-0115213010.3390/nano15020130Significance of Tool Coating Properties and Compacted Graphite Iron Microstructure for Tool Selection in Extreme MachiningAnna Maria Esposito0Qianxi He1Jose M. DePaiva2Stephen C. Veldhuis3McMaster Manufacturing Research Institute, McMaster University, Hamilton, ON L8P 0A6, CanadaDepartment of Mechanical Engineering, McGill University, Montreal, QC H3A 0C3, CanadaMcMaster Manufacturing Research Institute, McMaster University, Hamilton, ON L8P 0A6, CanadaMcMaster Manufacturing Research Institute, McMaster University, Hamilton, ON L8P 0A6, CanadaThis study aims to determine the extent to which coating composition and workpiece properties impact machinability and tool selection when turning Compacted Graphite Iron (CGI) under extreme roughing conditions. Two CGI workpieces, differing in pearlite content and graphite nodularity, were machined at a cutting speed of 180 m/min, feed rate of 0.18 mm/rev, and depth of cut of 3 mm. To assess the impact of tool properties across a wide range of commercially available tools, four diverse multilayered cemented carbide tools were evaluated: Tool A and Tool B with a thin AlTiSiN PVD coating, Tool C with a thick Al<sub>2</sub>O<sub>3</sub>-TiCN CVD coating, and Tool D with a thin Al<sub>2</sub>O<sub>3</sub>-TiC PVD coating. The machinability of CGI and wear mechanisms were analyzed using pre-cutting characterization, in-process optical microscopy, and post-test SEM analysis. The results revealed that CGI microstructural variations only affected tool life for Tool A, with a 110% increase in tool life between machining CGI Grade B and Grade A, but that the effects were negligible for all other tools. Tool C had a 250% and 70% longer tool life compared to the next best performance (Tool A) for CGI Grade A and CGI Grade B, respectively. With its thick CVD-coating, Tool C consistently outperformed the others due to its superior protection of the flank face and cutting edge under high-stress conditions. The cutting-induced stresses played a more significant role in the tool wear process than minor differences in workpiece microstructure or tool properties, and a thick CVD coating was most effective in addressing the tool wear effects for the extreme roughing conditions. However, differences in tool life for Tool A showed that tool behavior cannot be predicted based on a single system parameter, even for extreme conditions. Instead, tool properties, workpiece properties, cutting conditions, and their interactions should be considered collectively to evaluate the extent that an individual parameter impacts machinability. This research demonstrates that a comprehensive approach such as this can allow for more effective tool selection and thus lead to significant cost savings and more efficient manufacturing operations.https://www.mdpi.com/2079-4991/15/2/130compacted graphite iron (CGI)tool wearmachinabilityAlTiN-based coatingstool selection |
| spellingShingle | Anna Maria Esposito Qianxi He Jose M. DePaiva Stephen C. Veldhuis Significance of Tool Coating Properties and Compacted Graphite Iron Microstructure for Tool Selection in Extreme Machining Nanomaterials compacted graphite iron (CGI) tool wear machinability AlTiN-based coatings tool selection |
| title | Significance of Tool Coating Properties and Compacted Graphite Iron Microstructure for Tool Selection in Extreme Machining |
| title_full | Significance of Tool Coating Properties and Compacted Graphite Iron Microstructure for Tool Selection in Extreme Machining |
| title_fullStr | Significance of Tool Coating Properties and Compacted Graphite Iron Microstructure for Tool Selection in Extreme Machining |
| title_full_unstemmed | Significance of Tool Coating Properties and Compacted Graphite Iron Microstructure for Tool Selection in Extreme Machining |
| title_short | Significance of Tool Coating Properties and Compacted Graphite Iron Microstructure for Tool Selection in Extreme Machining |
| title_sort | significance of tool coating properties and compacted graphite iron microstructure for tool selection in extreme machining |
| topic | compacted graphite iron (CGI) tool wear machinability AlTiN-based coatings tool selection |
| url | https://www.mdpi.com/2079-4991/15/2/130 |
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