Wear 263 (2007) 1454–1458

Short communication

Characterizations of cutting tool flank wear-land contact

Jianwen Hu, Y. Kevin Chou ∗
Mechanical Engineering Department, The University of Alabama, Tuscaloosa, AL, USA
Received 2 September 2006; received in revised form 23 January 2007; accepted 26 January 2007
Available online 23 May 2007

Abstract
Metal deposition at the tool flank wear-land during machining is a common phenomenon, especially in machining aluminum alloys and annealed
steels. The cause of metal deposit has not been studied and the characteristics of the wear-land and deposit contact are not completely known. In
this study, a turning test was conducted using tungsten carbide (WC) tools with pre-generated wear-land to machine an aluminum alloy. The WC
tools after machining were prepared by metallographic means to expose the cross-section of the interfacial zone. The metallographic samples were
analyzed using etching, optical microscopy, scanning electron microscopy, energy dispersive by X-ray analysis, and microhardness testing.
The major findings include the following. The metal deposit is resistant to common etching solutions, shows high carbon and oxygen concentra-
tions, and has a very high hardness, all indicating fine microstructures resulted from the thermomechanical, and possibly chemical, process. The
WC at the contact interface has a thin heat-affected zone showing reduced hardness and different microstructures. In addition, the flank wear-land
subsurface has a decreased tungsten concentration, but an increased carbon concentration. After removing the metal deposit, the flank wear-land
consistently shows two topographically distinct zones when the wear-land is large; one close to the cutting edge has a plastic-contact feature and
the other has an elastic-contact feature. No significant difference in terms of microstructures and compositions was identified, except that the
plastic-contact zone was softer than the elastic-contact zone.
© 2007 Elsevier B.V. All rights reserved.

Keywords: Flank wear-land; Machining; Material characterizations; Tool wear

1. Introduction
Flank wear of a cutting tool is known to have detrimental
effects on part surface integrity including surface finish, residual
stress, microstructure alternations, etc. Flank wear is commonly
thought to result from abrasive wear of the cutting edge against
the machined surface and has been used to specify the tool life.
A ribbon-like layer of work materials, termed metal deposit, is
usually found to attach to the flank wear-land due to adhesion.
Growing and peeling of this thin layer from the wear-land may
cause or promote other forms of wear, such as diffusion and
adhesion. A number of studies have reported the effects of the
metal deposit on tool wear and machined surface in the past.
Using electron probe microanalysis, Zaima and Takatsuji exam-
ined the origin and growth mechanism of the deposit and found
that the deposit occurs when the width of wear-land reaches a
certain value regardless of the tool material and cutting speed
∗ Corresponding author.
E-mail address: kchou@eng.ua.edu (Y.K. Chou).
in Al–Si alloy machining [1]. The wear-land was increased due
to scratching of hard inclusions in the machined surface, and
simultaneous removal of the binder phase in the carbide tool.
Also commonly known, it is difficult to obtain good surface fin-
ish when the deposit accumulates on the wear-land surface [2].
Hirono et al. investigated the composition of the deposit and con-
cluded that the distribution of work materials in the deposit is
not uniform across the tool flank, rather related to the wear-land
size [3]. Nouari et al. performed dry machining tests of AA2024
aluminum alloy on a rigidly instrumented drilling bench using
cemented tungsten carbide (WC) drills and examined the topog-
raphy of the build-up edge and build-up layer formed at the tool
rake [4]. It was noted that as the cutting speed is increased, there
is a transition in wear mechanisms from abrasion and adhesion
to diffusion.
Although a number of experimental techniques have been
employed to study the metal deposit in the cutting process, no
coherent view has been obtained with regard to the characteris-
tics of the deposit and the wear-land subsurface. In particular,
the effects of a large wear-land on the mechanical property and
microstructure of the subsurface of tool flank have not been

0043-1648/$ – see front matter © 2007 Elsevier B.V. All rights reserved.
doi:10.1016/j.wear.2007.01.080
 J. Hu, Y.K. Chou / Wear 263 (2007) 1454–1458 1455

documented. In this study, turning aluminum (Al) 6061 alloy

by WC–Co cutting tools was conducted and the flank wear-
land as well as the deposit were characterized with respect to
the topography, microstructures, microhardness, and the com-
position. The objective was to better understand the interactions
between the metal deposit and the flank wear-land, which can
be practical in worn-tool machining studies.

2. Experimental procedures

The cutting tools used in machining were cemented WC–Co

inserts, with triangular shape (TPG432, 12.7 mm inscribed-
circle diameter), grade K313 (6 wt.% cobalt) from Kennametal
Inc., mounted on a CTGPL tool holder, which gives a 0◦ rake
angle and 11◦ relief angle. The work material used was alu-
minum 6061 alloy with a T-6 heat treatment. Both the tools and
workpieces (solid cylindrical bars) are commonly encountered
materials in machining practices.
The first part of the experiment was to prepare the flank
wear-lands. Three different widths of flank wear-land were gen-
erated by turning metal matrix composite bars and then the metal
deposit was cleaned by a 10% hydrofluoric (HF) acid solu-
tion. The maximum widths of the wear-land were 0.48, 0.80,
and 1.04 mm, coded as specimen Nos. 1, 2, and 3, respectively.
The worn tools were examined by optical microscopy and the
entire wear-land showed a surface abraded by reinforced par-
ticles in the composite workpiece. Next, the prepared cutting
inserts were used to machine Al 6061 alloy bars. The process
parameters used were 5 m/s cutting speed, 2 mm depth of cut, Fig. 1. Optical micrograph of flank wear-land, showing two distinct zones: (a)
and 0.05 mm/rev feed. The machining time was between 15 and upper wear-land and (b) lower wear-land (the insert is a drawing representing a
tool with the wear area indicated).
20 s and no wear-land increase was noticed after Al machin-
ing.
For worn tools after Al machining, these inserts were wear, caused by removing of the deposit layer from the tool flank
mounted in epoxy, positioned so that a cross-section normal wear-land. This distinct feature was not observed after compos-
to the cutting edge was generated after abrasive polish- ite machining and subsequent deposit cleaning. Moreover, the
ing. The exposed cross-section was further fine polished for dark area had more severe wear, evidence by the lower surface
microstructure examinations, microhardness tests, and com- than the shiny region, which is the other zone observed. Obser-
position analysis using energy dispersive X-ray spectroscopy vations of this shiny region indicate many ridges and grooves
(EDX). along the cutting direction, an evidence of abrasion. The ridges
and grooves resulted from local abrasion by hard constituents in
3. Results and discussion the workpiece. However, the entire area of zone II does not have
the adhesive wear feature as in zone I. According to the nature
3.1. Wear patterns and topography of contact, zones I and II are termed as the plastic-contact and
elastic-contact zones, respectively.
To examine the flank wear-land surface underneath the
deposit, the 1.04 mm wear-land case was duplicated to machine 3.2. Microstructures
Al bars, and the metal deposit was cleaned using 10% HF solu-
tion. An example of flank wear-land after Al machining and The three specimens, all with the deposit adhered to the
after deposit cleaning is shown, in optical micrographs (plane wear-land, were prepared for metallographic analysis and
view), in Fig. 1. The arrow mark shown in Fig. 1(a) indicates microstructural examinations. Fig. 2 presents a cross-sectional
the cutting edge. The free-of-contact area in Fig. 1(b) has the view of typical wear-land and deposit after final polishing; the
original grinding marks. It can be noted that the entire flank drawing insert shows schematically the cross-section being pol-
wear-land has two distinct zones. The zone closer to the cut- ished and observed. The cutting insert samples were etched
ting edge appears to be darker and covered by many shallow using Keller’s reagent, immersed and examined every 10 s.
pits. In addition, the original tool surface texture, abrasive scars, However, no microstructure was revealed even after 1 min repeti-
was flattened by material flows due to the relative motion of tion, and the specimens were eventually over-etched, evidenced
the machined surface. Such pattern can be attributed to adhesive by many pits at the sample surfaces as seen in Fig. 3. A
1456 J. Hu, Y.K. Chou / Wear 263 (2007) 1454–1458

Fig. 2. SEM photograph of the interface between wear-land and deposit of

specimen No. 3.

metallographic sample of the bulk Al 6061 alloy was also pre-

pared to compare against the deposit. Etching was conducted
by immersing the samples into Keller’s reagent for some 20 s.
The microstructure of the bulk sample, shown in Fig. 4(a),
was observed by optical microscopy and scanning electron
microscopy (SEM), showing equi-axed grains with a size of
between 15 and 20 ␮m.
Etched by Murakami’s reagent [5] for about 2 min, the
microstructures of the WC tool flank subsurface were examined
by SEM and shown in Fig. 5, also compared to bulk WC tool
microstructures (Fig. 4(b)). The carbide used has a grain size
of about 1–2 ␮m. The wear-land interface area in the plastic-
contact zone shows higher porosity than that in the elastic zone
and the etched bulk materials. The intense porosity suggests the Fig. 4. Microstructures, from SEM, of: (a) Al alloy workpiece and (b) WC tool.
removal (during etching) of possible Al diffused from the deposit
into the wear-land. On the other hand, ␩ phase (Co3 W3 C) was
3.3. Microhardness
reported to form in WC during steel cutting [6]. This ␩ phase,
attributed to the decarburization induced by high temperatures in
Microhardness tests were performed using a Vickers inden-
machining, has a dendritic structure and will result in strength
ter and due to the deposit width (less than 40 ␮m), a 25 gf load
reductions and facilitate tool failure. Because ␩ phase is less
was chosen. Under the 25 gf load, the measured hardness of
etching resistant [5], the higher porosity observed on the metal-
the bulk material was between 68 and 88. Note that, at 200 gf,
lographic samples may also be caused by the formation of the ␩
the bulk hardness is in the range of 117–133 Hv, which agreed
phase.
with the value found in the literature [7]. On the specimens,
six indentations were made and the average hardness numbers
were calculated. The values were between 352.0 and 355.2 Hv.
Compared to the bulk material, the microhardness of the deposit
increased substantially. Such microhardness characteristics are
consistent with other work [7,8], in accord with the microstruc-
ture changes (etching resistant).
To investigate the hardness changes at the wear-land subsur-
face, indentations were performed from the interface to a depth
of 100 ␮m. All tests were carried out in both the plastic-contact
and elastic-contact zones. The load applied was 500 gf with a
holding time of 10 s. The microhardness of the WC bulk was
measured as 2412 Hv in average. Indentations in each zone were
arranged in a three-by-three matrix pattern.
The indentation points were spaced equally about 30 ␮m in
both directions. The microhardness of the wear-land subsurface
Fig. 3. SEM photographs of the deposit on specimen No. 3, showing no grain of specimen No. 2 is shown in Fig. 6. The horizontal axis is
structure. the distance from the deposit interface. The error bars represent
 J. Hu, Y.K. Chou / Wear 263 (2007) 1454–1458
Fig. 5. SEM photographs of wear-land subsurface microstructures: (a) plastic
contact zone with intense porosity and (b) elastic-contact zone.
one standard deviation, calculated using the statistical analy-
sis of measured data. Evidently, these two zones show distinct
mechanical properties. Specifically, in the plastic-contact zone,
material softening is noted near the wear-land, ∼2100 Hv ver-
sus 2412 Hv of the bulk. In contrast, no significant hardness
change across the depth occurred in the elastic-contact zone.
The lower hardness in the plastic-contact zone can be attributed
to associated higher contact temperatures during machining,
reported in machining heat transfer studies, e.g. [11]. Because
Fig. 6. Wear-land subsurface microhardness profile of specimen No. 2.
1457
Fig. 7. Element concentration gradients in the plastic-contact zone: (a) Al, C,
W and (b) Mg, O, Co.
of greater shear stresses expected and the heat conduction con-
dition around the area, the plastic-contact zone, which is close
to the cutting edge, will have higher contact temperatures than
the elastic-contact zone.
3.4. Element analysis
Chemical compositions across the interface were examined
by EDX equipped in the SEM. In order to investigate the con-
centration gradient across the interface, the spot scan mode was
utilized and eight locations in a two-by-four matrix were tested
in the specimen. Each measured location was spaced 5 ␮m hor-
izontally and 300 ␮m vertically, and the upper and lower rows
were intentionally located in zones I and II, respectively. The
results show that the two zones have similar compositions. Fig. 7
presents the concentration gradients in atomic percentage of
major elements interested. The horizontal axis is the distance
from the interface, negative being in the deposit.
Mostly noted, carbon as well as oxygen were detected at both
sides of the interface. This WC–Co inserts used contain 6 wt.%
Co and 0.5 wt.% Cr. In both the deposit and the wear-land,
high carbon concentrations exceeding the nominal percentage
are noted. The C to W ratio is significantly larger than 1 near the
interface. The high carbon concentration indicates that tungsten
carbide decomposition might have occurred during machining.
The interstitial atoms like carbon possess a higher diffusion
coefficient than alloying elements such as tungsten, cobalt, and
chromium, by four to seven orders of magnitude [9]. If WC
decomposition occurs, free carbon atoms will diffuse into the
1458 J. Hu, Y.K. Chou / Wear 263 (2007) 1454–1458
material flow and the deposit layer adjacent to the tool flank in a
far more rapid pace. The mechanisms accounting for the loss of
tungsten could be complex. As soon as W atoms diffused into
the deposit, it may be immediately carried away by the mate-
rial flow. Additionally, the decomposed tungsten atoms may be
oxidized, forming WO3 [10], which is highly volatile at high
temperatures where diffusion occurs. Oxygen was also found to
diffuse to a depth of more than 7 ␮m at the tool flank wear-land
because the turning test was performed in the air.
The mechanisms accounting for the wear-land near-surface
softening may include: (1) composition changes due to diffu-
sion and chemical reactions and (2) high temperature softening.
However, the composition changes, as shown in Fig. 7, take
place within about 12 ␮m depth. On the other hand, microhard-
ness profiles show an affected zone over 50 ␮m. Thus, it seems
to be concluded that the subsurface softening at the wear-land
is predominantly the thermal effect. It has been reported that
WC substantially loses hot hardness at temperatures over 600 ◦ C
[12].
4. Conclusion
In this study, flank wear-land contact of WC tools in machin-
ing Al alloy was examined. The interfacial area between the
metal deposit and wear-land was characterized in microstruc-
tures, microhardness, and compositions. The results can be
summarized as follows:
• The metal deposit is etching resistant, shows high carbon and
oxygen concentrations, and has hardness much higher than the
original material, all indicating fine microstructures resulted
from the thermomechanical process, possibly chemical reac-
tions too.
• The flank wear-land shows distinctly two zones with different
topography, and based on contact nature, they can be referred
as the plastic-contact zone and the elastic-contact zone. No
significant difference in terms of microstructures and com-
positions was identified between the two zones, except that
the plastic-contact zone exhibits higher porosity after etching
and is softer than the elastic zone.
• Element analysis confirmed diffusion of Al from the work
material into the wear-land, evidenced from the porosity in
the etched microstructure of WC inserts. The analysis also
shows a decreased tungsten concentration, but an increased
carbon concentration, in the flank wear-land subsurface, indi-
cating WC decomposition, diffusion of carbon, and possible
tungsten oxidation and subsequent volatilization at high tem-
peratures.
• The plastic-contact zone at the wear-land contact interface
has a thin zone showing reduced hardness and different
microstructures. However, comparing the affected depth, the
microhardness results support thermal softening, instead of
the diffusion and dissolution of the tool and work materials,
as the major contribution.
Acknowledgements
This research is partially supported by NASA through
Alabama Space Grant Consortium.
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