materials

Article
Cutting Performance Evaluation of the Coated Tools
in High-Speed Milling of AISI 4340 Steel
Yuan Li, Guangming Zheng * , Xiang Cheng, Xianhai Yang, Rufeng Xu and Huaqiang Zhang
School of Mechanical Engineering, Shandong University of Technology; 266 West Xincun Road,
Zibo 255000, China; lysdut007@163.com (Y.L.); happychengx@163.com (X.C.); yxh@sdut.edu.cn (X.Y.);
xurufeng2003@126.com (R.X.); huaqiang.zhang@163.com (H.Z.)
* Correspondence: zhengguangming@sdut.edu.cn; Tel.: +86-533-2786972




Received: 3 September 2019; Accepted: 4 October 2019; Published: 7 October 2019


Abstract: The cutting performance of cutting tools in high-speed machining (HSM) is an important
factor restricting the machined surface integrity of the workpiece. The HSM of AISI 4340 is carried out
by using coated tools with TiN/TiCN/TiAlN multi-coating, TiAlN + TiN coating, TiCN + NbC coating,
and AlTiN coating, respectively. The cutting performance evaluation of the coated tools is revealed
by the chip morphology, cutting force, cutting temperature, and tool wear. The results show that the
serration and shear slip of the chips become more clear with the cutting speed. The lower cutting
force and cutting temperature are achieved by the TiN/TiCN/TiAlN multi-coated tool. The flank wear
was the dominant wear form in the milling process of AISI 4340. The dominant wear mechanisms
of the coated tools include the crater wear, coating chipping, adhesion, abrasion, and diffusion.
In general, a TiN/TiCN/TiAlN multi-coated tool is the most suitable tool for high-speed milling of
AISI 4340, due to the lower cutting force, the lower cutting temperature, and the high resistance of
the element diffusion.

Keywords: cutting performance; coated tool; wear mechanism; chip morphology; AISI 4340

1. Introduction
The high-strength steel is widely applied in the aerospace because of its superior features.
However, it is a typical difficult-to-cut material due to the high hardness, high plasticity, inferior
thermal conductivity, and high toughness [1–3]. Therefore, it is particularly important to explore the
tool materials and cutting parameters for achieving the highly-efficient machining of high-strength steel.
Coated tools are widely used in high-speed machining (HSM) of the difficult-to-cut materials,
due to their high temperature stability, high hardness, high plasticity, high toughness, excellent wear
resistance, and longer tool life [4,5].
In order to study the high-speed cutting process of AISI 4340 steel, a great deal of research has
been done on chip morphology, cutting force, cutting temperature, and a wear mechanism. The results
show that the color of chips can reflect the cutting temperature and cutting speed when AISI 4340
steel is cut at high speed. The appearance of bright blue color chips indicates that the cutting speed
is greater than 150 m/minute [6,7]. The chips are bright blue because the high cutting speeds result
in high cutting temperatures, while the high cutting temperature is due to the high frictional forces
between the flowing chips and the rake face [8,9]. The serrated chips are obtained when the AISI 4340
steel is cut at high speed, which can evaluate the cutting conditions. When the tooth-height of serrated
chips exceeds 0.3 microns, it means that the cutting speed and the depth of cut, respectively, exceed
150 m/minute and 1.0 mm [10]. In addition, the short-broken chip is easy to gain at a high cutting speed
condition [11]. The cutting parameters could be optimized by the 3D chip geometry driven analytical
model [12]. As for the formation of serrated chips, it is related to crack propagation [13]. Other types of

Materials 2019, 12, 3266; doi:10.3390/ma12193266 www.mdpi.com/journal/materials

Materials 2019, 12, 3266 2 of 16

high-strength steel, such as AISI H13, also have serrated chips in the process of high-speed cutting [14].
In addition, the chips are closely related to the tool wear and the cutting force. The results show that
the flow of chips can increase the probability of the coated tools’ adhesion wear [15]. Additionally, the
periodicity of the serrated chip is similar to the cyclicity of the cutting force [16].
The cutting force is an important response in the HSM process of AISI 4340 steel. On the one
hand, the cutting force is influenced by the type of coated tool. It is suggested that the cutting force
of the CVD (chemical vapor deposition) -TiCN/Al2 O3 /TiN multi-coated tool is bigger than that of
the PVD (physical vapor deposition) -TiAlN coated tool, due to the high friction [6]. On the other
hand, the cutting parameters affect the cutting force. Based on the central composite design (CCD),
the model of cutting force and cutting parameters is established. It is proven that the relationship
between cutting force and cutting parameters is the quadratic polynomial [17]. Moreover, the influence
of cutting speed on cutting force is more conspicuous [18]. In addition, based on the signal-to-noise
ratio model, the cutting parameters are optimized by the cutting force [19].
The cutting performance of the coatings is influenced greatly by the cutting temperature [20].
In this respect, the prediction model of cutting temperature is established by the least square method [21].
This model indicates that the cutting temperature increases with the growth of cutting speed, feed
per tooth, axial depth of cut, and radial depth cut. In order to predict the cutting temperature more
accurately, the chip-tool interface temperature model is established [22]. In addition to establishing
the model, it is also found that the thermal conductivity of the coating has an important effect on the
cutting temperature. The lower thermal conductivity of Ti0.41 Al0.59 N coating material and cemented
carbide will generate the instantaneous thermal barrier effect [23], which can effectively reduce the
cutting temperature. Moreover, the TiAlN coating can improve tool life, because of the lubricating
ability and anti-adhesion properties [24].
Tool wear is an important indicator for evaluating the cutting performance. Therefore, the
real-time monitoring of the flank wear is realized [25], while the normal force model is established to
predict the flank wear of the coated tool [26]. Furthermore, the empirical wear volume-loss equation is
proposed for abrasive wear, adhesive wear, and diffusion wear. In the aspect of wear type, the dominant
wear form of coated carbide tool is the flank wear in HSM of AISI 4340 steel [27]. The dominant wear
mechanisms of the coated tool are adhesion, abrasion, oxidation, and diffusion in HSM of high-strength
steel [6,28,29]. The cutting-edge collapses and exposed tool substrate of the TiAlN coated tool and
TiCN/Al2 O3 /TiN multi-coated tool are common [30], and the AlTiN coated tool is more prone to
chipping [31].
Based on the summary of current research on high-speed cutting of AISI 4340 steel, it was
found that the main research contents are the prediction model of cutting force as well as the cutting
temperature and tool wear, while the tool wear is studied. However, the most suitable coated tool for
the HSM of AISI 4340 is not indicated. In the work, the TiN/TiCN/TiAlN multi-coated tool, TiAlN +
TiN coated tool, TiCN + NbC coated tool, and AlTiN coated tool are used in the HSM of AISI 4340 steel.
The cutting performance of the coated tools is evaluated by chip morphology, cutting force, cutting
temperature, wear type, and wear mechanism in order to determine the most suitable coated tool for
HSM of 4340 steel.

2. Materials and Methods

2.1. Workpiece Material

The workpiece material is AISI 4340 steel. The main chemical compositions of the workpiece are
Ni 1.65%, Cr 0.72%, Mn 0.65%, C 0.40%, Mo 0.22%, Si 0.15%, P 0.01%, and S 0.01%. The tensile strength,
yield strength, elongation, and reduction in area of AISI 4340 steel is 1462 MPa, 1379 MPa, at 12% and
55%, respectively [32]. The hardness of AISI 4340 steel is 42–44 HRC, which is achieved by vacuum
heat treatment. The heat treatment process is completed by the manufacturer of the workpiece material.
Materials 2019, 12, 3266 3 of 16

This material is made by the Dongguan Chang’an Huaming Die Steel Business Department (Dongguan,
China). The length, width, and height of the workpiece are 100 mm, 100 mm, and 60 mm, respectively.

2.2. Cutting Tool Material

There are four types of coated tools used in the experiments. The first one is a PVD-coated carbide
tool with a single coating layer made of AlTiN, with a grade number of KC522M. The second one
is a PVD-coated carbide tool with a composite coating layer made of TiAlN and TiN, with grade
number of PR830. The third one is a multilayer PVD-coated carbide tool consisting of three layers
made by different coating material ordered from the outer to the inner layer as: TiN, TiCN, and
TiAIN, respectively, with grade number of ACM300. The last one is a PVD-coated ceramic tool with a
composite coating layer made of TiCN and NbC, with a grade number of TN100M. The tool hilt type
of four coated tools is BT40-ER32-70. In addition, the cutter arbor types of KC522M and ACM300 is,
respectively, 20A03R028A20ED10 and WEX2020E, while the cutter arbor type of PR830 and TN100M
is MEC25-S20-11T. Furthermore, the cutting-edge angle of all coated tools is 90◦ . The cutting-edge
inclination of KC522M and ACM300 are, respectively, 15◦ and 14◦ , while the cutting-edge inclination
of PR830 and TN100M is 13◦ [33–35]. The geometries of coating tools have been shown in Table 1.
The insert type and the diameter of cutter arbor (d) are shown in Table 2.

Table 1. The geometries of coating tools.

Length Width Thickness Nose Radius

Grade No.
(mm) (mm) (mm) (mm)
KC522M 12.05 6.75 3.75 0.40
PR830 11.00 6.70 3.80 0.80
ACM300 12.00 7.00 3.58 0.80
TN100M 11.00 6.70 3.80 0.80

Table 2. Insert type and the diameter of cutter arbor.

Diameter of Cutter Arbor

Grade No. Insert Type Manufacturer
d (mm)
KC522M EDCT10T304PDERLD 20 Kennametal, PA, USA
PR830 BDMT-11T308ER-JT 25 Kyocera, Japan
ACM300 AXMT 123508PEER-E 20 Sumitomo, Japan
TN100M BDMT-11T308ER-JT 25 Kyocera, Japan

2.3. Experimental Design

The dry down milling tests of AISI 4340 steel are carried out by the NC milling machine center
with a 3-axis, which is made in Doosan Machine Tools Co., Ltd. (Yantai, China), and model DNM-415,
with a maximum speed of 12,000 r/min. To avoid the influence of the inserts, only one insert is used in
the milling process. The cutting length for every cutting parameter is 300 mm. The cutting force is
measured by the cutting force measurement system (Model: 9257B, Kistler, Switzerland), while the
cutting temperature is measured by the thermal infrared imager (Model: A300, FLIR, Portland, OR,
USA). In the process of temperature measurement, the material of the workpiece is unchanged, and
the material of the coated tool is changed. To avoid the influence of the coated tool on temperature
measurement, the temperature reflected by the workpiece (or chip) is selected as cutting temperature.
Therefore, only the thermal diffusivity of the workpiece is set at 0.95. FLIR A300 is automatically
calibrated, while the resolution and frame speed of it is 320 × 240 pixels and 30 Hz. The experimental
design of the high-speed milling of AISI 4340 steel and the cutting parameters is shown in Figure 1
and Table 3, respectively. According to Table 3, each coated tool is tested in 40 different sets of
cutting parameters. Furthermore, three tests were performed for each set of cutting parameters, and
the average of three results is taken as experimental data. The tool wear mechanisms and the chip
Materials 2019, 12, 3266 4 of 16

morphology are observed by a scanning electron microscope (SEM, Model: Quanta 250, FEI, Hillsboro,
OR, USA). Chemical elements of the worn-out tools are detected by the energy dispersive spectrometer
(EDS, Model: Quanta 250, FEI, Hillsboro, OR, USA).

Table 3. Cutting parameters.

Cutting Speed Feed Per Tooth Axial Depth of Cut Radial Depth Cut
No.
vc (m/min) f z (mm/z) ap (mm) ae (mm)
1 280 0.02 0.2 2
2 280 0.02 0.2 4
3 280 0.02 0.4 2
4 280 0.02 0.4 4
5 280 0.04 0.2 2
6 280 0.04 0.2 4
7 280 0.04 0.4 2
8 280 0.04 0.4 4
9 320 0.02 0.2 2
10 320 0.02 0.2 4
11 320 0.02 0.4 2
12 320 0.02 0.4 4
13 320 0.04 0.2 2
14 320 0.04 0.2 4
15 320 0.04 0.4 2
16 320 0.04 0.4 4
17 360 0.02 0.2 2
18 360 0.02 0.2 4
19 360 0.02 0.4 2
20 360 0.02 0.4 4
21 360 0.04 0.2 2
22 360 0.04 0.2 4
23 360 0.04 0.4 2
24 360 0.04 0.4 4
25 400 0.02 0.2 2
26 400 0.02 0.2 4
27 400 0.02 0.4 2
28 400 0.02 0.4 4
29 400 0.04 0.2 2
30 400 0.04 0.2 4
31 400 0.04 0.4 2
32 400 0.04 0.4 4
33 440 0.02 0.2 2
34 440 0.02 0.2 4
35 440 0.02 0.4 2
36 440 0.02 0.4 4
37 440 0.04 0.2 2
38 440 0.04 0.2 4
39 440 0.04 0.4 2
40 440 0.04 0.4 4
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Materials 2019, 12, x FOR PEER REVIEW 5 of 16

Figure 1. Experimental design of the high-speed milling of AISI 4340 steel.

Figure 1. Experimental design of the high-speed milling of AISI 4340 steel.
3. Results and Discussion
3. Results and Discussion
3.1. Chip Morphology
3.1. Chip Morphology
The micrographs of chip surfaces flowing from the rake face at vc = 440 m/min, f z = 0.04 mm/z,
ap = The
0.4 mm, and ae = 4ofmm
micrographs chiparesurfaces
presentedflowing from the
in Figure 2. Itrake face at
is found vc =the
that 440 m/min,
crack causedfz = 0.04 mm/z,
by the AlTiN ap
=coated
0.4 mm, tool and the TiAlN + TiN coated tool is more serious than that caused by the TiN/TiCN/TiAlN
and a e = 4 mm are presented in Figure 2. It is found that the crack caused by the AlTiN
coated tool and
multi-coated theThe
tool. TiAlN TiCN + NbC
+ TiN coated tooltool
coated is more serious
acquires the than
densethat caused
burrs chip.by It the TiN/TiCN/TiAlN
is indirectly reflected
multi-coated
that the tool wear tool. of The TiCNTiCN + NbC
+ NbC coated
coated tooltool acquires the
is enormous. Asdense
can be burrs
seenchip. It is indirectly
in Figure reflected
2a, the micrograph
that thesurfaces
of chip tool wear gotof byTiCN the +TiN/TiCN/TiAlN
NbC coated toolmulti-coated
is enormous.tool As can be smoothest,
is the seen in Figure which 2a, the micrograph
is accompanied
of
withchipnosurfaces got by
clear burrs. It isthe TiN/TiCN/TiAlN
suggested that the tool multi-coated tool is the smoothest,
wear of TiN/TiCN/TiAlN which isisaccompanied
multi-coating smaller than
with
that of the other three tools. Figure 3 shows the micrographs of chip surfaces away from theisrake
no clear burrs. It is suggested that the tool wear of TiN/TiCN/TiAlN multi-coating smaller
face
at vc = 360 m/min, f z = 0.04 mm/z, ap = 0.4 mm, and ae = 4 mm, (a) TiN/TiCN/TiAlN multi-coating,
than that of the other three tools. Figure 3 shows the micrographs of chip surfaces away from the rake
face at vc =coating,
(b) AlTiN 360 m/min, fz = 0.04
(c) TiAlN + TiN
mm/z, ap = 0.4 mm,
composite andand
coating, ae =(d)4 mm,
TiCN (a)+TiN/TiCN/TiAlN
NbC composite coating. multi-coating,
As can
(b)
be seen from Figure 3, the texture of the chip surface has been curved. This proves the existencecan
AlTiN coating, (c) TiAlN + TiN composite coating, and (d) TiCN + NbC composite coating. As of
be seendeformation.
plastic from Figure However, 3, the texture of the chip
the difference in surface has been curved.
plastic deformation of theThis
chip proves
surface the existence
obtained of
by the
plastic deformation.
four coated tools is not However,
clear. Itthecandifference
be concluded in plastic
that the deformation
serrated degree of the ofchip
chips surface
obtainedobtained
by fourby
the four coated tools is not clear. It can be concluded that the serrated
coated tools is different under the same cutting parameter. The formation of the serrated chips is the degree of chips obtained by
four
resultcoated
of stresstools is different
hardening under
caused bythe same force
cutting cuttingand parameter.
softeningThe causedformation
by the of the serrated
cutting chips
temperature.
is the result of stress hardening caused by cutting force and
When the softening effect is strengthened, the stress that prevents the deformation of material will be softening caused by the cutting
temperature.
reduced. Until When the softening
the softening effect
exceeds theisstress
strengthened,
hardening, theitstress that prevents
will cause the deformation
local deformation and then of
material will be chips.
produce serrated reduced. Until the
In addition, thesoftening
chip serration exceedsshape theof stress hardening, it multi-coated
the TiN/TiCN/TiAlN will cause local tool
and AlTiN coated tool was significant and uniform when compared to the TiAlN + TiN coated tool and
deformation and then produce serrated chips. In addition, the chip serration shape of the
the TiCN + NbC coated
TiN/TiCN/TiAlN multi-coated
tool. This tool andthat
shows AlTiNstresscoated
hardeningtool and was softening
significant andTiN/TiCN/TiAlN
of the uniform when
compared
multi-coated to tool
the and
TiAlN the+AlTiN
TiN coated
coated tool
tool andis morethestable
TiCNthan + NbC thatcoated + TiN
tool. This
of the TiAlN shows
coated that
toolstress
and
the TiCN + NbC coated tool. It is also found that the crack propagation of the TiAlN + TiN coated tool
hardening and softening of the TiN/TiCN/TiAlN multi-coated tool and the AlTiN coated tool is more
stable
and the than
TiCN that+ of
NbC thecoated
TiAlN tool + TiNis coated tool and
more serious thanthethat
TiCN of +theNbC coated tool. It is
TiN/TiCN/TiAlN also found that
multi-coated tool
and the AlTiN coated tool. This indicates that the cutting force of the TiAlN + TiN coated tool and the
the crack propagation of the TiAlN + TiN coated tool and the TiCN + NbC coated tool is more serious
than
TiCNthat + NbCof the TiN/TiCN/TiAlN
coated tool is largermulti-coated
than that of the toolTiN/TiCN/TiAlN
and the AlTiN coated tool. This
multi-coated indicates
tool and thethatAlTiNthe
cutting force This
coated tool. of theoccurs
TiAlNbecause+ TiN coated tool and
the severe crack thepropagation
TiCN + NbCiscoated causedtool is larger
by large than forces
cutting that ofandthe
TiN/TiCN/TiAlN multi-coated
alternating mechanical loads. tool and the AlTiN coated tool. This occurs because the severe crack
propagation is caused by large cutting forces and alternating mechanical loads.
Materials 2019, 12, 3266 6 of 16
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Materials 2019,
2019, 12,
12, xx FOR
FOR PEER
PEER REVIEW
REVIEW 66 of
of 16
16

Figure
Figure 2.
2. Micrographs
Micrographsof
Micrographs ofofchip
chipsurfaces
chip surfacesflowing
surfaces flowingfrom
flowing fromrake
from rakeface
rake face at vvcc v==c 440
atat
face m/min,
= 440
440 m/min, ffzz == f0.04
m/min, mm/z,
z = 0.04
0.04 mm/z, aapp ==
mm/z,
0.4
ap =mm,
0.4 mm, and aaee == a44e =
and and
0.4 mm, mm,
mm,
4 mm,(a) TiN/TiCN/TiAlN
(a) (a)
TiN/TiCN/TiAlN
TiN/TiCN/TiAlN multi-coating,
multi-coating,
multi-coating,(b)
(b)(b)AlTiNAlTiNcoating,
AlTiN coating,(c)
coating, (c)TiAlN
(c) TiAlN +++ TiN
TiAlN TiN
composite
composite coating,
coating, and and (d)
(d) TiCN
TiCN ++ NbC
NbC composite
composite coating.
coating.

Figure
Figure 3. Micrographs of chip surfaces away from the rake face at vvcc == 360 m/min, ffzz == 0.04 mm/z,
mm/z, aapp ==
Figure 3.
3. Micrographs
Micrographsof ofchip
chipsurfaces
surfacesaway
awayfrom
fromthe
therake
rakeface atat
face vc 360 m/min,
= 360 m/min, f0.04
z = 0.04 mm/z,
0.4
0.4 mm,
mm, and
and a
a ee =
= 4
4 mm,
mm, (a)
(a) TiN/TiCN/TiAlN
TiN/TiCN/TiAlN multi-coating,
multi-coating, (b)
(b) AlTiN
AlTiN coating,
coating,
ap = 0.4 mm, and ae = 4 mm, (a) TiN/TiCN/TiAlN multi-coating, (b) AlTiN coating, (c) TiAlN +TiN (c)
(c) TiAlN
TiAlN +TiN
+TiN
composite
composite coating, and
coating, and
composite coating, (d)
and (d) TiCN
(d) TiCN
TiCN + + NbC
+ NbC composite
NbC composite coating.
composite coating.
coating.

3.2. Cutting
Cutting Force
Force
The value
valueofofcutting
cutting force
force (Fyxx,,FF
(Fx , F z )yy,varies
Fzz) varies withTherefore,
with time. time. Therefore, the maximum
the maximum force is
force is considered
considered
to analyze theto analyze
effect ofthe effect ofand
coatings coatings
cutting and cutting parameters
parameters on theforce.
on the cutting cutting force. 4Figures
Figures and 5 4show and
5the
show theofeffect
effect of coatings
coatings on cutting
on cutting force at force at different
different cuttingcutting parameters,
parameters, from from
whichwhich
can becan be seen
seen that
that
the Fthe Fzz (axial
z (axial force)force)
is theishighest
the highest
component component of theofcutting
the cutting
force.force. It illustrates
It illustrates thatFzthe
that the Fzz is
is the the
main
main component of the cutting force. This is due to the extrusion and friction between the flank face
of the coated tool and workpiece being greater than that between the rank face of the coated tool and
Materials 2019, 12, 3266 7 of 16

component
Materials 2019, of
12, the
x FOR cutting
PEER REVIEWforce. This is due to the extrusion and friction between the flank face 7 of of
16
Materials 2019, 12, x FOR PEER REVIEW 7 of 16
the coated tool and workpiece being greater than that between the rank face of the coated tool and
workpiece. This
workpiece. This is is also
also proven
proven by the fact
by the fact that
that the
the main
main wear
wear form form is is the
the flank
flank wear.
wear. Moreover,
Moreover, thethe
workpiece.
cutting forceThis
(F ,isFyalso
, F )proven
is by thewith
improved fact cutting
that thespeed
main wear
when form
the f is
, athe, a flank
, and wear.
coating Moreover,
material the
are
cutting force (Fx , Fy , Fz ) is improved with cutting speed when the f z , ap , ae , and coating material are
x z z p e
cutting force (F
maintaining constant, x, Fy, Fz) is improved with cutting speed when the fz, ap, ae, and coating material are
constant, which which can can also
also be
be seen
seen from
from Figures
Figures 44 and
and 5. 5. InIn addition,
addition, it it is
is observed
observed from
from
maintaining
maintaining
Figures 4a constant,
and 5a that which
the can also
cutting be is
force seen from Figures
increased with f z
4, aand
p, and5. In ae , addition,
when theitcutting
is observed
speedfrom
and
Figures 4a and 5a that the cutting force is increased with f z , ap , and ae , when the cutting speed and
Figures 4a and
coating material
material is5a that
is taking the
taking the cutting force
the constant is
constant value. increased
value. As
As can with
can be fz, ap, and ae, when the cutting speed and
be observed
observed in in Figures
Figures 44 and and 5,
5, the
the cutting
cutting force
force
coating
coating
of the material is takingmulti-coated
TiN/TiCN/TiAlN the constanttool
value.
is Asminimum
the can be observed
magnitude in Figures
at the 4same
and 5, the cutting
cutting force
parameter.
of the TiN/TiCN/TiAlN multi-coated tool is the minimum magnitude at the same cutting parameter.
of the TiN/TiCN/TiAlN
Therefore, for all
all of that,multi-coated
of that, tool is themulti-coated
the TiN/TiCN/TiAlN
TiN/TiCN/TiAlN minimum magnitude
tool is theatmost
is the the same
most cutting
suitable tool parameter.
for milling
milling
Therefore, for the multi-coated tool suitable tool for
Therefore,
AISI 4340 for
4340 steel all
steel to of that,
to achieve
achieve the the TiN/TiCN/TiAlN
the smallest
smallest cutting multi-coated
cutting force.
force. tool is the most suitable tool for milling
AISI
AISI 4340 steel to achieve the smallest cutting force.

Figure 4. Effect of coatings on cutting force at (a) vc = 280 m/min, (b) vc = 360 m/min, and (c) vc = 440
Figure
Figure 4. Effect of
of coatings
coatingson oncutting
cuttingforce (a) vc = 280 m/min, (b) vc = 360 m/min, and (c) vc =
force at(a)
m/min,4.fz Effect
= 0.02 mm/z, ap = 0.2 mm, and ae = at
2 mm.vc = 280 m/min, (b) vc = 360 m/min, and (c) vc = 440
440 m/min, f z = 0.02 mm/z, ap = 0.2 mm, and ae = 2 mm.
m/min, fz = 0.02 mm/z, ap = 0.2 mm, and ae = 2 mm.

Figure 5. Cont.
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Materials 2019, 12, x FOR PEER REVIEW 8 of 16

Figure 5.
Figure 5. Effect
Effect ofof coatings
coatings on
on cutting
cuttingforce (a)vvc c= =280
forceatat(a) 280m/min,
m/min,(b)(b) = 360
vc v=c 360 m/min, andand
m/min, (c) (c) c =
vc =v440
m/min,
440 fz = 0.04
Figure
m/min, 5. = mm/z,
f z Effect ap = 0.4
0.04ofmm/z,
coatings =
mm,
ap on and
cutting
0.4 aand
e = 4at
mm,force = v4c mm.
amm.
e(a) = 280 m/min, (b) vc = 360 m/min, and (c) vc = 440
m/min, fz = 0.04 mm/z, ap = 0.4 mm, and ae = 4 mm.
3.3. Cutting Temperature
3.3. Cutting Temperature
3.3. Cutting Temperature
The infrared thermal
The infrared thermalimage imageofofthe thehigh-speed
high-speed milling
milling experiment
experiment is exhibited
is exhibited in Figure
in Figure 6. The6.
The The infrared thermal image of the high-speed milling experiment is exhibited in Figure 6. The
red red triangle
triangle is anis automatic
an automatic function
function of of
thethe temperaturemeasurement
temperature measurementsystem systemto to mark
mark the the highest
highest
red triangle
temperature is an
point. In automatic
the process function
of of the temperature
temperature measurement
measurement, the system to measurement
temperature mark the highest system
temperature point. In the process of temperature measurement, the temperature measurement
temperature point. In the process of temperature measurement, the temperature measurement
automatically
system displays
automatically a red
displays triangle
a red at the highest temperature in the area. The red triangle appears at
system automatically displays a redtriangle
triangle atat the highesttemperature
the highest temperature in the
in the area.
area. The The red triangle
red triangle
the point
appears where
at
appears the the tip
at point
iswhere
where
the point
in contact
tiptipiswith
thethe the
isinincontact
workpiece,
contact with
and it is concluded
theworkpiece,
with the workpiece, and
and isthat the highest
it isitconcluded
concluded that that
temperature
the highest
the highest
is acquired
temperature at
temperaturethe contact
is acquired
is acquired position
at atthe between
thecontact the
contact position tip and the workpiece.
betweenthe
position between Then,
thetiptipandand the
thethe maximum
workpiece.
workpiece. valuetheof the
Then,Then, the
cutting
maximum temperature
maximum valuevalue in the
of the
of the machining
cutting
cutting temperature
temperaturearea wasin investigated
in the
the machiningin
machining thewas
area
area study.
was investigated
investigated in thein study.
the study.

Figure
Figure 6. Infrared
6. Infrared thermalimage
thermal image of the
the high-speed
high-speedmilling
millingexperiment.
experiment.

Figure Figure
7 presents Figurethe
7 presents 6.
theInfrared
effectof
effect ofthermal
cuttingimage
cutting of theon
parameters
parameters high-speed
cutting
on cutting milling
temperature experiment.
temperatureof the coated
of thetools.
coated Thetools.
cutting temperature of TiAlN + TiN coated tool changes with
The cutting temperature of TiAlN + TiN coated tool changes with the cutting parameters, as shown the cutting parameters, as shown in in
Figure
Figure 7
7a.presents
For the the
lines effect
A and of
B cutting
in Figure parameters
7a, the cutting on cutting
temperature temperature
Figure 7a. For the lines A and B in Figure 7a, the cutting temperature is slightly raised at vc = 280~320 is slightly of the
raised coated
at v tools.
c = 280~320 The
m/min
cutting and vc = 400~440
temperature of TiAlN m/min.
+ TiNAdditionally,
coated toolthe growth with
changes rate ofthecutting
cutting temperature
parameters, is improved
as shown in
m/min and vc = 400~440 m/min. Additionally, the growth rate of cutting temperature is improved
greatly
Figure 7a. at v = 320~400 m/min. However, the value of line B is larger than that of line A, because of
at vFor the linesm/min. A and BHowever,
in Figurethe 7a,value
the cutting
of linetemperature is slightly raisedA, at vc = 280~320
c
greatly
theand c = 320~400
improvement
B is larger than
of the feed per tooth from 0.02 mm/z to 0.04 mm/z. The cutting temperature of Line
that of line because of the
m/min
improvement v c = 400~440 m/min. Additionally, the growth rate of cutting temperature is improved
C in Figure 7a increases gradually when vc accelerates from 320 m/minute to 440 m/minute. In C in
of the feed per tooth from 0.02 mm/z to 0.04 mm/z. The cutting temperature of Line
greatly
Figure 7aatincreases
vc = 320~400 m/min.
gradually However,
when vof the value of320
linem/minute
B is larger to than that of lineInA, becausethe of
addition, the cutting temperature c accelerates from
line D is fluctuant and sharply increased 440 m/minute.
with cutting speed addition,at
the improvement
cutting of the feed per tooth from 0.02 mm/z to 0.04 mm/z. The
of line D is fluctuant and sharply increased with cutting speed at ap = 0.4 mm. cutting temperature of Line
ap =temperature
0.4 mm.
C inTheFigureThe 7a
cuttingincreases
cutting temperature temperaturegradually
of TiCN
of TiCN+when
NbC+ NbCvcoated
c accelerates from 320 m/minute to 440 m/minute. In
tooltool
coated changes
changeswith thethe
with cutting parameters,
cutting parameters, as as
shown
addition,
shown
in Figure the cutting
7b.in For
Figure the7b.temperature
linesFor E,theF,lines of line
andE,G,F,the D is
andcuttingfluctuant
G, the cutting and
temperature sharply
temperature
slowly increased
slowly with
increases
increases with cutting
with speed
cutting
cutting speed.at
ap = 0.4
However, mm.
speed.the However,
value ofthe value
line H isofclearly
line H is clearlythan
greater greaterthatthan that ofE,lines
of lines E, F,G.and
F, and ThisG. is
Thisdue is to
due to increase
the the
of ap from 0.2 mm to 0.4 mm. It is shown that the effect of doubling ap on cutting temperature as
The cutting
increase of a temperature
p from 0.2 mm toof
0.4 TiCN
mm. It+isNbC
shown coated
that thetool changes
effect of with
doubling apthe
on cutting
cutting parameters,
temperature is
shown in Figure 7b. For f z the
or alines E, F, and G, the cutting temperature slowly increases with cutting
greater than doubling e on cutting temperature under the same cutting speed for the TiCN +
speed. However, the value of line H is clearly greater than that of lines E, F, and G. This is due to the
NbC coated tool.
increase of ap from 0.2 mm to 0.4 mm. It is shown that the effect of doubling ap on cutting temperature
 Materials 2019, 12, x FOR PEER REVIEW 9 of 16

is greater than doubling fz or ae on cutting temperature under the same cutting speed for the TiCN +
Materials 2019, 12, 3266 9 of 16
NbC coated tool.

Figure
Figure 7. 7. Effect
Effect of of cutting
cutting parameters
parameters onon cutting
cutting temperature,
temperature, (a)(a) TiAlN
TiAlN + TiN
+ TiN coating,
coating, (b)(b) TiCN
TiCN +
+ NbC
NbC coating, (c) TiN/TiCN/TiAlN multi-coating, and (d) AlTiN
coating, (c) TiN/TiCN/TiAlN multi-coating, and (d) AlTiN coating. coating.

The The cuttingtemperature

cutting temperatureof ofthe
the TiN/TiCN/TiAlN
TiN/TiCN/TiAlN coated coated tool toolchanges
changeswith withcutting
cutting parameters,
parameters,
as shown in Figure 7c. The cutting temperature of Line I has a slight
as shown in Figure 7c. The cutting temperature of Line I has a slight rise at vc = 280~360 m/min. rise at v c = 280~360 m/min.

Afterward, it rapidly increases at vc = 360~440 m/min. The cutting temperature of Line J is improved
Afterward, it rapidly increases at vc = 360~440 m/min. The cutting temperature of Line J is improved
somewhat linearly with cutting speed. In addition, the cutting temperature of Line K rises sharply at
somewhat linearly with cutting speed. In addition, the cutting temperature of Line K rises sharply at
vc = 280~320 m/min, and increases slowly at vc = 320~440 m/min.
vc = 280~320 m/min, and increases slowly at vc = 320~440 m/min.
The cutting temperature of the AlTiN coated tool changes with cutting parameters, as shown in
The cutting temperature of the AlTiN coated tool changes with cutting parameters, as shown in
Figure 7d. For line M, the value of the cutting temperature is slightly raised at vc = 280~320 m/minute.
Figure 7d. For line M, the value of the cutting temperature is slightly raised at vc = 280~320 m/minute.
As vc increases from 320 to 400 m/min, the cutting temperature rapidly increases. When the increase
Asofvcvincreases from 320 to 400 m/min, the cutting temperature rapidly increases. When the increase of
c grows from 400 to 440 m/minute, the rise in cutting temperature grows sharply. For lines N, O,
vc and
grows P, from 400 to temperature
the cutting 440 m/minute, the risewith
increases in cutting temperature
the increase of fz, apgrows
, or ae.sharply.
In addition,For lines N, O,of
the value and
P, the cutting temperature increases
cutting temperature increases slightly. with the increase of f z , a p , or a e . In addition, the value of cutting
temperature increases
In general, slightly.
the cutting temperature can be improved with the increase of the cutting parameters.
AsInthe general,
cutting the cutting temperature
parameters can be improved
increase, the volume of materialwith removedthe increase
per unitoftime
the iscutting
improved.parameters.
As a
Asresult,
the cutting parameters
the plastic deformation increase, the volume
of the workpiece of material
material and chip removed
becomesper moreunit time The
severe. is improved.
energy
Asgenerated
a result, the byplastic
plasticdeformation
deformation of the workpieceinto
is converted material
cutting andheat,chip becomes
which leadsmoretosevere.
the riseTheofenergy
the
temperature
generated in thedeformation
by plastic cutting area.is Atconverted
the same into
time,cutting
the influence
heat, which of cutting
leadstemperature
to the rise ofon thethe thermal
temperature
in conductivity
the cutting area. of AISI 4340
At the steeltime,
same is considered, because
the influence the thermal
of cutting temperatureconductivity
on the of AISI4340
thermal steel is
conductivity
reduced with the increase of cutting temperature [36]. The low thermal
of AISI 4340 steel is considered, because the thermal conductivity of AISI4340 steel is reduced with conductivity can lead to thethe
reduction of heat dissipation and the increase of cutting temperature.
increase of cutting temperature [36]. The low thermal conductivity can lead to the reduction of heat
On and
dissipation the theother hand,ofatcutting
increase the same cutting parameter, the cutting temperature of the
temperature.
TiN/TiCN/TiAlN multi-coated tool is lower
On the other hand, at the same cutting parameter, than that theof the othertemperature
cutting coated tool, which can be seen in
of the TiN/TiCN/TiAlN
multi-coated tool is lower than that of the other coated tool, which can be seen in Figure 7.
The TiN/TiCN/TiAlN coating is a multi-layer PVD-coating, and AlTiN coating is a single PVD-coating,
while the TiAlN + TiN coating and TiCN + NbC coating are the composite PVD-coating. The order
Materials 2019, 12, x FOR PEER REVIEW 10 of 16

Figure 7.
Materials The
2019, 12,TiN/TiCN/TiAlN
3266 coating is a multi-layer PVD-coating, and AlTiN coating is a 10 single
of 16
PVD-coating, while the TiAlN + TiN coating and TiCN + NbC coating are the composite PVD-coating.
The order of the thermal conductivity is TiCN coating > TiN coating > TiAlN coating [37]. However,
of thethe
only thermal conductivity
TiN/TiCN/TiAlN is TiCN coating
multi-coated > TiN
tool has middle >
thecoating TiAlN
layer coating
of TiCN. [37]. as
TiCN, However,
the middleonly the
layer,
TiN/TiCN/TiAlN multi-coated tool has the middle layer of TiCN. TiCN, as the middle layer,
increases the heat dissipation of the TiN/TiCN/TiAlN multi-coated tool. When the heat is transferred increases
the heatTiCN
to the dissipation
layer, of theheat
the TiN/TiCN/TiAlN multi-coated
is rapidly dissipated due tool. When
to the highthe heat is transferred
thermal conductivity to of
theTiCN.
TiCN
layer, the heat is rapidly dissipated due to the high thermal conductivity of TiCN. Therefore,
Therefore, the cutting temperature of the TiN/TiCN/TiAlN multi-coated tool is lower than that of the the cutting
temperature
other coated of the TiN/TiCN/TiAlN multi-coated tool is lower than that of the other coated tool.
tool.

3.4. Wear Type and Wear Mechanism

3.4. Wear Type and Wear Mechanism
Figure 8 presents the rake wear and flank wear at vc = 280 m/min, f z = 0.02 mm, ap = 0.2 mm, and
Figure 8 presents the rake wear and flank wear at vc = 280 m/min, fz = 0.02 mm, ap = 0.2 mm, and
ae = 2 mm. For the TiAlN + TiN coated tool and TiCN + NbC coated tool, the wear of the rake face
ae = 2 mm. For the TiAlN + TiN coated tool and TiCN + NbC coated tool, the wear of the rake face is
is less than that of the flank face. Therefore, the flank wear is a dominant wear type in high-speed
less than that of the flank face. Therefore, the flank wear is a dominant wear type in high-speed
milling of AISI 4340 steel.
milling of AISI 4340 steel.

Figure 8.
Figure 8. Rake
Rake wear
wear and
and flank
flank wear
wear at
at vvcc ==280
280m/min,
m/min,fzf z= =
0.02 mm,
0.02 ap a=p 0.2
mm, mm,
= 0.2 andand
mm, ae =ae2 =mm, (a)
2 mm,
TiAlN + TiN coating, and (b) TiCN + NbC coating.
(a) TiAlN + TiN coating, and (b) TiCN + NbC coating.

micrograph of
The SEM micrograph of tool
tool wear
wear at at vvcc = 280 m/min, fzz==0.02
= 280 mm,aap p= =0.2
0.02mm, 0.2mm,
mm,andandaea=e 2= mm
2 mm is
shown
is shown in Figure
in Figure9, from which
9, from can be
which canseen that the
be seen thatflank wear width
the flank of the TiN/TiCN/TiAlN
wear width of the TiN/TiCN/TiAlN multi-
coated tool istool
multi-coated the is
minimum.
the minimum. The micro crackcrack
The micro on the ontip
theand
tip the
andcoating
the coating chipping are found
chipping on the
are found on
worn surface of the AlTiN coated tool (Figure 9b). As can be observed in Figures
the worn surface of the AlTiN coated tool (Figure 9b). As can be observed in Figure 9a,c, the flank wear 9a and 9c, the flank
wear width
width got by got
TiAlN by +TiAlN + TiNtool
TiN coated coated toolserious
is more is more serious
than that gotthanby that got by the TiN/TiCN/TiAlN
the TiN/TiCN/TiAlN multi-coated
multi-coated
tool. tool.chipping
The coating The coating TiAlN +of
of thechipping TiN thecoated
TiAlNtool + TiN coated
is also tool ison
observed also
theobserved
flank faceon the flank
(Figure 9c).
For the TiCN + NbC coated tool, the flank wear width is the maximum and the chip bonding and
face (Figure 9c). For the TiCN + NbC coated tool, the flank wear width is the maximum and the chip
bonding wear
abrasive and abrasive wear on
is also found is also foundface,
the flank on the flank
as can beface, as can be
illustrated illustrated
in Figure in Figure
9d. Figure 9d. Figure
10 shows the
10 shows
SEM the SEMofmicrograph
micrograph tool wear atofvctool= 440 wear
m/min, = 0.04
at vc f=z 440 mm, fazp==0.04
m/min, 0.4 mm, and ap = a0.4
e =mm,
4 mm.and Forae =4
the
mm. For the TiN/TiCN/TiAlN
TiN/TiCN/TiAlN multi-coated multi-coated
tool, the damaged tool, the damaged
coating coating on
is presented is presented
the flank faceon the flank 10a).
(Figure face
(Figure
For 10a). For
the AlTiN the AlTiN
coated coated
tool, the tool, the
collapse andcollapse and tearare
tear of coating of observed
coating areasobserved
the dominantas thewear
dominanttype
wear type
(Figure (Figure
10b). 10b). In aaddition,
In addition, a typical
typical chip bonding chip isbonding
observed is observed
on the flank on the
faceflank face
of the of thecoating.
AlTiN AlTiN
coating. Additionally,
Additionally, the micro the micro
crack and crack and chip
chip bonding arebonding
observed areonobserved
the wornon the worn
surface TiAlN +
of thesurface of TiN
the
TiAlN +tool
coated TiN coated10c).
(Figure tool As
(Figure
can be 10c). As caninbeFigure
exhibited exhibited
10d,in theFigure 10d, the
tool failure toolTiCN
of the + NbC
failure of thecoated
TiCN
+ NbC
tool coated caused
is mainly tool is mainly caused
by coating by coating
chipping, crack, chipping,
and sharp crack, and sharp collapse.
collapse.
Materials 2019, 12, 3266 11 of 16

Materials 2019, 12, x FOR PEER REVIEW 11 of 16

Materials 2019, 12, x FOR PEER REVIEW 11 of 16

Figure 9. SEM micrograph of tool wear at vc = 280 m/min, fz = 0.02 mm, ap = 0.2 mm, and ae = 2 mm, (a)
Figure 9. SEM
Figure micrograph
9. SEM of of
micrograph tool wear
tool wear at vvcc ==280
280m/min, = 0.02
m/min,fz f=z0.02 mm,+mm, = 0.2and
ap mm, mm, ae =and ae =(a)2 mm,
TiN/TiCN/TiAlN multi-coated tool, (b) at
AlTiN coated tool, (c) TiAlN aTiN
p = 0.2
coated tool, and 2(d)
mm,TiCN
(a) TiN/TiCN/TiAlN
TiN/TiCN/TiAlN multi-coated tool, (b) AlTiN coated tool, (c) TiAlN + TiN coated tool, and (d) TiCN
+ NbC coated tool.multi-coated tool, (b) AlTiN coated tool, (c) TiAlN + TiN coated tool, and (d) TiCN
+ NbC coated
+ NbC tool.tool.
coated

Figure 10. SEM micrograph of tool wear at vc = 440 m/min, fz = 0.04 mm, ap = 0.4 mm, and ae = 4 mm,
Figure
(a) 10. SEM micrograph
TiN/TiCN/TiAlN of tool tool,
multi-coated wear(b)
at vc = 440coated
m/min, fz = 0.04 mm, a+p =TiN
0.4 mm, and ae = 4 mm,
Figure 10. SEM micrograph of tool wear at vcAlTiN
= 440 m/min,tool,
f z =(c) TiAlN
0.04 mm, ap = 0.4coated
mm, tool,
andand (d)4 mm,
ae =
(a)
TiCNTiN/TiCN/TiAlN
+ NbC coated multi-coated tool, (b) AlTiN coated tool, (c) TiAlN + TiN coated tool, and (d)
tool.
(a) TiN/TiCN/TiAlN multi-coated tool, (b) AlTiN coated tool, (c) TiAlN + TiN coated tool, and (d) TiCN
TiCN + NbC coated tool.
+ NbC coated tool.
As can be seen in Figures 9 and 10, the sharpening, chipping, crack, and collapse is not found on
As can
the worn be seen
surface in Figures
of the 9 and 10, the
TiN/TiCN/TiAlN sharpening,tool.
multi-coated chipping, crack, and
It is inferred that collapse is not foundand
the wear-resistance on
As
the can
wornbe seen of
surface in the
Figures 9 and 10, the
TiN/TiCN/TiAlN sharpening,
multi-coated tool. chipping,
It is inferredcrack,
that and
the collapse is not
wear-resistance andfound
shock resistance of the TiN/TiCN/TiAlN multi-coated tool is better than that of the other three tools.
on the worn
shock surfaceof
resistance ofthe
theTiN/TiCN/TiAlN
TiN/TiCN/TiAlN multi-coated tool. It is inferred of that the wear-resistance
The chipping of the coating layer and multi-coated
abrasive wear toolisis better
not than
found thatthe
on the other
flank threeof
surface tools.
the
and shock
The resistance of the TiN/TiCN/TiAlN multi-coated tool is better than
TiN/TiCN/TiAlN multi-coated tool. The coating adhesion and cohesion between coating and the
chipping of the coating layer and abrasive wear is not found on the that
flank of the
surface other
of thethree
tools.TiN/TiCN/TiAlN
The chipping
substrate of the coating
multi-coated
of the TiN/TiCN/TiAlN layer
tool. and abrasive
The coating
multi-coated adhesion
tool wear
is comparedand is tonot
thatfound
cohesion the on
ofbetween the flank
coating
other coated andsurface
tool. In of
the
substrate of the TiN/TiCN/TiAlN multi-coated tool is compared to that
the TiN/TiCN/TiAlN multi-coated tool. The coating adhesion and cohesion between coating andof the other coated tool. In
the substrate of the TiN/TiCN/TiAlN multi-coated tool is compared to that of the other coated tool.
Materials 2019, 12, 3266 12 of 16

Materials 2019, 12, x FOR PEER REVIEW 12 of 16

In addition, the TiN/TiCN/TiAlN multi-coated tool has no serious coating damage, which can also
addition, the TiN/TiCN/TiAlN multi-coated tool has no serious coating damage, which can also
prove the result.
prove the result.
The EDS analysis at vc = 440 m/min, f z = 0.04 mm/z, ap = 0.4 mm, and ae = 4 mm is shown in
The EDS analysis at vc = 440 m/min, fz = 0.04 mm/z, ap = 0.4 mm, and ae = 4 mm is shown in Figure
Figure 11. For the TiN/TiCN/TiAlN multi-coated tool (Figure 11a), the proportion of the Ti element in
11. For the TiN/TiCN/TiAlN multi-coated tool (Figure 11a), the proportion of the Ti element in the
the coating material is higher. It is suggested that the coating is relatively complete. This is consistent
coating material is higher. It is suggested that the coating is relatively complete. This is consistent
with
withthe result
the resultofoftool
toolwear
wear(Figure
(Figure 10a). However, the
10a). However, theproportion
proportionofofthe
theTiTielement
elementin in
thethe other
other three
three
coating materials is lower, as shown in Figure 11b–d. It is proven that the coating is
coating materials is lower, as shown in Figures 11b–11d. It is proven that the coating is severely severely damaged.
This is also shown
damaged. by the
This is also tool by
shown wear,
the as shown
tool wear,in
asFigure
shown 10b–d. Additionally,
in Figure the oxygen
10b–d. Additionally, the element
oxygen is
present on the flank face of the four coated tools. It is demonstrated that the oxidative
element is present on the flank face of the four coated tools. It is demonstrated that the oxidative wear wear is an
important factor leading to tool failure.
is an important factor leading to tool failure.

Figure
Figure 11.
11. Cont.
Cont.
Materials 2019, 12, 3266 13 of 16
Materials 2019, 12, x FOR PEER REVIEW 13 of 16

Figure
Figure 11.11.EDS
EDSanalysis
analysisatatvcvc== 440
440 m/min,
m/min, ffzz ==0.04
0.04mm/z,
mm/z,aap p= =0.40.4mm,
mm,and
andae a=e 4=mm. (a) (a)
4 mm. Area A in
Area A in
Figure 10a. (b) Area B in Figure 10b. (c) Area C in Figure 10c. (d) Area D in Figure
Figure 10a. (b) Area B in Figure 10b. (c) Area C in Figure 10c. (d) Area D in Figure 10d. 10d.

Moreover,
Moreover, thetheFeFe elementthat
element thatdiffused
diffusedfrom fromthetheworkpiece
workpieceisistested
testedon onthe
theworn
wornsurface
surface(Figure
(Figure11).
It is suggested that the adhesive layer is formed on the flank face. However, the adhesive layer
11). It is suggested that the adhesive layer is formed on the flank face. However, the adhesive layer is
is unstable,
unstable, whichwhich
cancancausecause
thethe flaking
flaking of of coating
coating ononthe
theflank
flankface
faceand
andaccelerate
accelerate tool
tool wear.
wear. Thus,
Thus,itit is
is proven
proven thatthat
the the adhesion
adhesion is an
is an important
important cause
cause ofof tool
tool wear.
wear.
The content of the Fe element on the flank face of the TiN/TiCN/TiAlN multi-coated tool is the
The content of the Fe element on the flank face of the TiN/TiCN/TiAlN multi-coated tool is the
lowest (Figure 11a), while the flank wear width is minimal and the wear form is single (Figure 10a).
lowest (Figure 11a), while the flank wear width is minimal and the wear form is single (Figure 10a).
The content of the Fe element on the flank face of the TiCN + NbC coated tool is the highest (Figure
The content of the Fe element on the flank face of the TiCN + NbC coated tool is the highest (Figure 11d),
11d), while the flank wear is the most serious (Figure 10d). It is concluded that the wear states of
while the flank wear is the most serious (Figure 10d). It is concluded that the wear states of coated tools
coated tools are related to the content of the Fe element. Because of the diffusion of the Fe element,
arethe
related to the content of the Fe element. Because of the diffusion of the Fe element, the strength of
strength of the coated tool is seriously reduced, which results in sharpening, chipping, and
the coatedTherefore,
peeling. tool is seriously
it could reduced,
be inferred which
that the results in sharpening,
Fe element accelerateschipping,
tool wear and peeling. Therefore,
in high-speed milling
it could be
of AISI 4340. inferred that the Fe element accelerates tool wear in high-speed milling of AISI 4340.
InInsummary,
summary, thethecutting
cuttingperformance
performance of the TiN/TiCN/TiAlN
of the TiN/TiCN/TiAlN multi-coated
multi-coated tooltool
is theis best
the among
best
the four coated
among the fourtools.
coatedFirst,
tools.the chip
First, the surface
chip surface gained by TiN/TiCN/TiAlN
gained by TiN/TiCN/TiAlN multi-coated
multi-coated tools
toolsisisthe
smoothest.
the smoothest. Second, the cutting
Second, force
the cutting of the
force TiN/TiCN/TiAlN
of the TiN/TiCN/TiAlN multi-coated
multi-coated tool is is
tool minimal.
minimal.Third,Third,the
high
the heat
highdissipation
heat dissipationperformance
performanceof theofTiN/TiCN/TiAlN
the TiN/TiCN/TiAlN multi-coated
multi-coated tool tool
contributed
contributed the the
lower
cutting
lowertemperature.
cutting temperature.Lastly, the flank
Lastly, thewear
flank width
wearof the TiN/TiCN/TiAlN
width of the TiN/TiCN/TiAlN multi-coated tool is tool
multi-coated minimal.
is
minimal.
4. Conclusions
4. Conclusions
• The burrs and the smoothness’s degree of chip surfaces flowing from the rake face can reflect tool
 wear.The burrs and the
Generally, thesmoothness’s
dense burrs degree of chip surfaces
and non-smooth flowingare
chip surface from the rakeinface
acquired thecan reflect of
condition
tool wear.
serious tool Generally,
wear. The the chip dense burrsflowing
surfaces and non-smooth
from the chip
rake surface are acquired
face obtained by theinTiN/TiCN/TiAlN
the condition
of serious tool
multi-coated tool iswear. The chipand
the smoothest, surfaces
the flankflowing from of
wear width thetherake face obtained
TiN/TiCN/TiAlN by the
multi-coated
TiN/TiCN/TiAlN
tool is minimal. multi-coated tool is the smoothest, and the flank wear width of the
• The cutting force (Fx , Fy , Fz ) is tool
TiN/TiCN/TiAlN multi-coated is minimal.
improved with the increase of the cutting parameter (vc , f z , ap ,
 The cutting force (Fx, Fy, Fz) is improved with the increase of the cutting parameter (vc, fz, ap, and
and ae ). The Fz (axial force) is the main cutting force. The value of Fz is the maximum cutting
ae). The Fz (axial force) is the main cutting force. The value of Fz is the maximum cutting force
force component when the coated tools are used for high-speed milling of AISI 4340 steel.
component when the coated tools are used for high-speed milling of AISI 4340 steel.
• TiCN, as the middle layer of the coated tool, can improve heat dissipation of the coated tool. This is
 TiCN, as the middle layer of the coated tool, can improve heat dissipation of the coated tool.
also
This theisreason
also the why the TiN/TiCN/TiAlN
reason why the TiN/TiCN/TiAlN multi-coated tool has the
multi-coated lowest
tool cutting
has the lowest temperature.
cutting
However,
temperature. However, the heat dissipation of TiCN is reduced when TiCN and NbC act ascoating.
the heat dissipation of TiCN is reduced when TiCN and NbC act as the composite the
• The flank wear
composite of the coated tools is the dominant wear type in high-speed milling of AISI 4340
coating.
 steel. The chipping
The flank wear of the ofcoated
coating, abrasive
tools wear, collapse,
is the dominant wear type andin chipping
high-speed are the dominant
milling of AISI 4340 wear
mechanisms.
steel. The chipping of coating, abrasive wear, collapse, and chipping are the dominant wearthe
The flank wear of the TiN/TiCN/TiAlN multi-coated tool is lower than that of
other three tools.
mechanisms. The flank wear of the TiN/TiCN/TiAlN multi-coated tool is lower than that of the
other three tools.
Materials 2019, 12, 3266 14 of 16

• Among the four coated tools, the TiN/TiCN/TiAlN multi-coated tool is the most suitable for the
high-speed milling of AISI 4340, because of the smallest cutting force and the lowest cutting
temperature, which could achieve minimal flank wear.

Author Contributions: Conceptualization and writing—review and editing, G.Z. Formal analysis and
writing—original draft preparation, Y.L. Software and data curation, X.C. Investigation, X.Y. Validation, R.X.
Supervision, H.Z.
Funding: The National Key Research and Development Program of China (No. 2018YFB2001400), the Project
funded by China Postdoctoral Science Foundation (No. 2019M652439), the National Natural Science Foundation
of China (No. 51505264), and the Zibo City-Shandong University of Technology Cooperative Projects
(No. 2018ZBXC003) supported this work.
Acknowledgments: We give thanks to X.J. Liu for grammar revision.
Conflicts of Interest: The authors declare no conflict of interest.

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