Cutting Performance of Coated Cemented Carbide Tool in Driven Rotary Cutting of Hardened Steel
Hideharu Kato*1,, Noriyuki Takase*2, Kentaro Watanabe*3, Tatsuya Shikimura*4, and Kazuyuki Kubota*5
*1Kanazawa Institute of Technology
3-1 Yatsukaho, Hakusan, Ishikawa 924-0838, Japan
*2Yokowo Co., Ltd., Tomioka, Japan
*3Toshiba Machine Co., Ltd., Numazu, Japan
*4Takamatsu Machinery Co., Ltd., Hakusan, Japan
*5Mitsubishi Hitachi Tool Engineering, Ltd., Yasu, Japan
Recently, cutting has replaced grinding in the finishing process for hardened steel. However, tool damage is a major problem in high-efficiency operations that use high-speed cutting and high-feed rate conditions rather than more conventional cutting conditions. Therefore, a new cutting technique that can realize high-efficiency cutting is desired. In our previous study, the processing efficiency was improved three to five times compared with conventional hardened steel cutting by driven rotary cutting. Furthermore, to attain high efficiency, the resistance of the tool material to wear and oxidation must be improved. In this study, the cutting performance of tools with an Al-rich coating, which improves oxidation resistance, is investigated for high cutting speed applications. In the present experiments, the flank wear of the Al-rich tool was less than 40 μm at a high cutting speed of 2.51 m/s, even for a cutting length of 10.0 km. Additionally, the Al-rich tool wear advanced progressively without flaking. In contrast, the conventional TiAlN-coated tools exhibited serious failure at cutting lengths of 3.0 km. It is thought that the difference in the oxidation resistance of the two tools influenced the cutting performance. Therefore, the tool with the Al-rich coating can operate with a high efficiency even at high cutting speeds.
-  Y. Okada, “Trends of Structural Steels for Automobiles,” Denki Seiko (Electr. Furn. Steel), Vol.69, No.1, pp. 49-56, 1998.
-  T. Ikeda and H. Satoh, “Phase formation and characterization of hard coatings in the Ti-Al-N system prepared by the cathodic arc ion plating method,” Thin Solid Film, Vol.195, Issues 1-2, pp. 99-110, 1991.
-  K. Shintani, M. Ueki, and Y. Fjimura, “Optimum Tool geometry of CBN tool for continuous turning of carburized steel,” Int. J. of Machine Tools & Manufacture, Vol.29, Issue 3, pp. 403-413, 1989.
-  K. Shintani, M. Ueki, and Y. Fjimura, “Optimum Cutting Tool geometry when interrupted cutting carburized steel by CBN tool,” Int. J. of Machine Tools & Manufacture, Vol.29, Issue 3, pp. 415-423, 1989.
-  T. Egawa, T. Ichikizaki, M. Kuroda, Y. Hiasa, and H. Tsukamoto, “Wear mechanism of cBN tool in cutting of hardened steel,” The Japan Society for Precision Engineering, Vol.61, No.6, pp. 809-819, 1995.
-  N. Narutaki, Y. Yamane, and M. Takeuchi, “Wear of CBN cutting tool,” The Japan Society for Precision Engineering, Vol.45, No.2, pp. 201-207, 1979.
-  Y. Yamada, T. Aoki, Y. Tanaka, and K. Wakihara, “Cutting Performance of Coated Carbide Tools for Hard Work Material,” Trans. of the Japan Society of Mechanical Engineers, Vol.60, No.577, pp. 2906-2910, 1994.
-  S. Enomoto and M. Kato, “Cutting characteristics of CBN cutting tools in turning chromium molybdenum steels of various hardnesses,” The Japan Society for Precision Engineering, Vol.55, No.6, pp. 1079-1084, 1989.
-  T.Ishikawa, F. Obata, and K. Inoue, “Wear mechanism of TiSiN-coated cutting tools on hgih-apeed cutting of hardened die steel,” Japan Society for Precision Engineering, Vol.75, No.12, pp. 1439-1443, 2009.
-  W. Konig, R. Fritsch, and D. Karnmermeier, “New approaches to characterizing the performance of coated cutting tools,” CIRP Annals – Manufacturing Technology, Vol.41, Issue 1, pp. 49-54, 1992.
-  S. Lei and W. Liu, “High-speed machining of titanium alloys using the driven rotary tool,” Int. J. of Tools and Manufacture, Vol.42, Issue 6, pp. 653-661, 2002.
-  H. Sasahara, A. Kato, H. Nakajima, H. Yamamoto, T. Muraki, and M. Tsutsumi, “High-speed rotary cutting of difficult-to-cut materials on multitasking lathe,” Int. J. of Machine Tools and Manufacture, Vol.48, Issues 7-8, pp. 841-850, 2008.
-  A. Hosokawa, T. Ueda, R. Onishi, R. Tanaka, and T. Furumoto, “Turning of difficult-to-machine materials with actively driven rotary tool,” CIRP Annals – Manufacturing Technology, Vol.59, Issue 1, pp. 89-92, 2010.
-  H. Sasahara, K. Satake, W. Takahashi et al., “The effect of oil mist supply on cutting point temperature and tool wear in driven rotary cutting,” Precision Engineering, Vol.48, pp. 158-163, 2017.
-  H. Kato, T. Shikimura, Y. Morimoto, K. Shintani, K. Kubota, and K. Nakagaki, “Study on High-efficiency finish turning of carburized hrdened steel with driven rotary cutting,” Int. J. Automation Technol., Vol.7, No.3, pp. 321-328, 2013.
-  T. Ikeda and H. Satoh, “High-temperature oxidation and wear resistance of Ti-Al-N hard coatings formed by PVD method,” J. of the Japan Institute of Metals, Vol.57, No.8, pp. 919-925, 1993.
-  A. Hörling, L. Hultman, M. Odén, J. Sjölén, and L. Karlsson, “Mechanical properties and machining performance of Ti1-xAlxN-coated cutting tools,” Surface and Coatings Technology, Vol.191, Issues 2-3, pp. 384-392, 2005.
-  A. Hörling, L. Hultman, and M. Odén, “Thermal stability of arc evaporated high aluminum-content Ti1-xAlxN thin films,” J. of Vacuum Science & Technology, A 20, pp. 1815-1823, 2002.
-  H. Kato, K. Ito, A. Kitamura, N. Ikenaga, and K. Kubota, “Study on milling of super elasto-plastic β type titanium alloy (Verification of processing characteristics and selection of optimum cutting conditions),” Trans. of the JSME, Vol.83, No.855, p. 17-00258, 2017.
-  K. Yamamoto, T. Sato, K. Takahara, and K. Hanaguri, “Properties of (Ti,Cr,Al)N coatings with high Al content deposited by new plasma enhanced arc-cathode,” Surface and Coatings Technology, Vols.174-175, pp. 620-626, 2003.
This article is published under a Creative Commons Attribution-NoDerivatives 4.0 International License.