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at www.sciencedirect.com
Procedia CIRP 00 (2018) 000–000

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Procedia CIRP 00 (2018) 000–000
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CIRP 77 (2018) 606–609
www.elsevier.com/locate/procedia

8th CIRP Conference on High Performance Cutting (HPC 2018)

8th CIRP Conference on High Performance Cutting (HPC 2018)
Tool Wear Mechanisms of pcBN tooling during High-Speed Machining of
Tool Wear Mechanisms
28th CIRP of pcBN
Design tooling
Conference, Mayduring High-Speed
2018, Nantes, France Machining of
Gray Cast Iron
Gray Cast Iron
A new Fredrik
methodology to
a, analyze the functional and physical architecture of
Schultheissa,*, Volodymyr Bushlyaaa, Filip Lenrickaa, Daniel Johanssonaa,
existing products
Fredrik for an
Schultheiss assembly
*,Stefan
Volodymyr oriented
Bushlya
Kristiansson b , Filipproduct
Ståhlaa ,family
Lenrick
, Jan-Eric identification
Daniel Johansson ,
b
Stefan Kristiansson , Jan-Eric Ståhl
Division of Production and Materials Engineering, Lund University, 221 00 Lund, Sweden
a
Paul
a Stief *, Jean-Yves
Division of Production
Automotive
b Dantan,
and Materials
Components Floby AB,Alain
Engineering, Lund Etienne,
University,
521 51 Floby, Ali
221 00
Sweden Siadat
Lund, Sweden
b
Automotive Components Floby AB, 521 51 Floby, Sweden
Écoleauthor.
* Corresponding Nationale
Tel.:Supérieure d’Arts etE-mail
+46-46-222-8520. Métiers, Arts etfredrik.schultheiss@iprod.lth.se
address: Métiers ParisTech, LCFC EA 4495, 4 Rue Augustin Fresnel, Metz 57078, France
* Corresponding author. Tel.: +46-46-222-8520. E-mail address: fredrik.schultheiss@iprod.lth.se

* Corresponding author. Tel.: +33 3 87 37 54 30; E-mail address: paul.stief@ensam.eu

Abstract
Abstract
The presence of graphite particles in gray cast iron commonly implies a good machinability, especially if compared to common steels. However,
Abstract
The presence
increasing of graphite
industrial particles
demands haveinresulted
gray cast
iniron
a newcommonly
interest forimplies a goodmachining
high-speed machinability, especially
of these if compared
materials with higherto common steels.
performing toolHowever,
materials
increasing
than the industrial demands
traditionally used. havetheresulted
Thus, in presented
research a new interest
in forpaper
this high-speed
focuses machining
on of these
evaluating the materials
active with
tool higher
wear performing
mechanisms toolhigh-speed
while materials
In today’s business environment, the trend towards more product variety and customization is unbroken. Due to this development, the need of
than the traditionally
machining EN-GJL-250 used. Thus,
gray cast the
iron research
with pcBNpresented
tools in this
with papercomposition,
different focuses on evaluating
geometries the active
and edge tool wear mechanisms
preparations. In while
addition to high-speed
the expected
agile and reconfigurable production systems emerged to cope with various products and product families. To design and optimize production
machining EN-GJL-250
flank and notch gray castofiron
wear, formation MnS,with pcBN
SiO 2, andtools
Al2Owith different
3 tool composition,
protection layers wasgeometries
found on theandworn
edgesurfaces.
preparations. In addition to
Non-chamfered the exhibited
tools expected
systems as well as to choose the optimal product matches, product analysis methods are needed. Indeed, most of the known methods aim to
flank
higherand notch wear,
tendency formation
towards of MnS,
notching. SiO2, and
In general, the Al 2O3 were
tools tool protection layersa was
found to have found
rather smallon wear
the worn
landsurfaces.
but largeNon-chamfered tools exhibited
edged radius indicating edge
analyze a product or one product family on the physical level. Different product families, however, may differ largely in terms of the number and
higher
roundingtendency
being a towards notching.
more accurate wearIncriterion.
general, the tools were found to have a rather small wear land but large edged radius indicating edge
nature of components. This fact impedes an efficient comparison and choice of appropriate product family combinations for the production
rounding being a more accurate wear criterion.
system. A new methodology is proposed to analyze existing products in view of their functional and physical architecture. The aim is to cluster
© 2018
these The Authors.
products Publishedoriented
in new assembly by Elsevier Ltd.families
product This is an
foropen access articleofunder
the optimization the assembly
existing CC BY-NC-ND
lines andlicense
the creation of future reconfigurable
© 2018
© 2018 The Authors.
The Authors. Published
Published by by Elsevier
Elsevier Ltd.
Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/3.0/)
assembly
This is ansystems. Based
open access on Datum
article under Flow
the CCChain, the physical
BY-NC-ND licensestructure of the products is analyzed. Functional subassemblies are identified, and
(https://creativecommons.org/licenses/by-nc-nd/4.0/)
(http://creativecommons.org/licenses/by-nc-nd/3.0/)
aPeer-review
Selection
functionaland under
analysisresponsibility
peer-review underofresponsibility
is performed. the International
Moreover, Scientific
of the
a hybrid functionalCommittee
International of theCommittee
andScientific
physical 8th CIRP Conference
architecture ofgraph
the 8th on High
CIRP
(HyFPAG) Performance
Conference
is Cutting
on High
the output (HPC the
whichPerformance
depicts
Peer-review
2018).
Cutting (HPC under responsibility of the International Scientific Committee of the 8th CIRP Conference on High Performance Cutting (HPC
2018).
similarity between product families by providing design support to both, production system planners and product designers. An illustrative
2018).
example of a nail-clipper is used to explain the proposed methodology. An industrial case study on two product families of steering columns of
Keywords: High-Speed Machining; Turning; Gray Cast Iron; Tool Wear; pcBN
thyssenkrupp Presta France is then carried out to give a first industrial evaluation of the proposed approach.
Keywords: High-Speed Machining; Turning; Gray Cast Iron; Tool Wear; pcBN
© 2017 The Authors. Published by Elsevier B.V.
Peer-review under responsibility of the scientific committee of the 28th CIRP Design Conference 2018.
1. Introduction still unknown in terms of the wear mechanisms active while
Keywords: Assembly; Design method; Family identification
1. Introduction still unknown
machining grayin terms of theespecially
cast iron, wear mechanisms
when utilizingactive while
high-
High-speed machining is an efficient mean for enhancing machining gray cast iron, especially
performance cutting tools such as cBN. Thus, the purpose when utilizing high-
of
High-speed machining is an efficient mean
productivity due to its high material removal rate while not for enhancing performance cutting tools such as cBN. Thus,
the study presented in this paper has been to analyze the tool the purpose of
productivity
1.necessitating
Introduction due to its high material removal
large machines. However, high-speed machining rate while not the
wear
of study presented
the mechanisms
product range in
active this
and whilepaper has been to
machiningmanufactured
characteristics analyze the
gray cast ironand/or tool
with
necessitating
directly correlateslarge machines. However, high-speed
to high temperatures machining
at the cutting edge, wear
pcBNmechanisms
assembled cutting active
tools.
in this As found
system. while
In thisbymachining
Gastelthe
context, etgray cast
al. [7],
main ironpcBN
the
challenge with
in
directly
negatively correlates
Due to affecting
the fast to high
the tool temperatures
life [1]. Previous
development at
in the the cutting
investigations
domain onedge,
of pcBN cutting
binder phase
modelling tools.
and isanalysisAs
not stable found
is now by
at high Gastel
cutting
not only et al. [7],
speeds,
to cope the
with pcBN
i.e.single
high
negatively
high-speedaffecting
communication and the
machining tool
anof life [1].
gray
ongoing cast Previous
ironofhave
trend investigations
reported and
digitization on
that binder phase
temperatures,
products, is not
decomposing
a limited stable range
product at high
into boron cutting speeds,
and nitrogen
or existing i.e.
productoxides. high
As
families,
high-speed
digitalization, machining
polycrystallinemanufacturing of gray
cubic boron nitride, cast
enterprises iron
pcBN, have reported
cutting important
are facing that
tools are temperatures,
reported
but also toby decomposing
beKato,
able toShintani
analyze and into
and toboron
Sumiya and
compare nitrogen
[8],products oxides.
binderless As
cubic
to define
polycrystalline
advantageous
challenges in in cubic boron
both prolonging
today’s nitride, pcBN, cutting
tool life and increasing
market environments: tools
a continuing are
the reported
boron
new by
nitride,
product Kato, Shintani
bcBN,It can
families. couldand Sumiya
be expected
be observed [8], binderless
to outperform
that classical cubic
existing
advantageous
material removal
tendency towards in both prolonging
rate [2-5].
reduction of producttool development
life and increasing
times andthe boron
traditional
product nitride,
pcBNare
families bcBN,
during
regroupedcould
the inbe
machining expected
function ofofgray to
castoutperform
clients oriron. This
features.
material
Gray removal
shortened cast ironrate
product is a[2-5].
common
lifecycles. engineering
In addition, therematerial used in
is an increasing traditional pcBN during
notion is assembly
However, contradicted by
oriented theChen
machining
product al. of
[9]gray
et families arecast
who iron.
found
hardly This
tobcBN
find.
Gray cast iron
multipleofapplications,
demand is
customization, a common
e.g. being engineering
engineatparts,
the same material
braketimediscs
in andused
gear
a global in notion
inferior is contradicted
On thetoproduct
pcBN infamily by
termslevel, Chen
of tool et al. [9]
life while
products who
differ found
machining bcBN
mainly inwhite two
multiple
boxes. Due
competition applications,
with e.g. engine
to itscompetitors
extensive use parts, thebrake
in industry,
all over world.discs
moreThisand
thangear
46
trend, inferior
cast iron
main toandpcBN in terms
(i) the of
corroborated
characteristics: by tool
number life
the resultswhile machining
published
of components by (ii)
and white
Reuter
the
boxes.
millionisDue
which metric totons
inducingits of
extensive
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development industry,
from moretothan
cast worldwide
macro 46
during
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[10].
type iron and corroborated
However,
components the (e.g. by the results
highmechanical,
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electrical, by Reuter
conductivity
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million
2016 [6],
markets, metric
results tons
efficient of gray castisiron
in machining
diminished was
sizescast
important.
lot dueworldwide
However, during
much
to augmenting is [10].
impact However,
Classicalstrength the
of high
bcBNhardness,
methodologies as compared
considering thermal to conductivity
mainly pcBN
single [11] and
was
products
2016 [6], efficient machining is important.
product varieties (high-volume to low-volume production) [1]. However, much is impact strength of bcBN as compared
or solitary, already existing product families analyze the to pcBN [11] was
To cope with
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10.1016/j.procir.2018.08.201
 Fredrik Schultheiss et al. / Procedia CIRP 77 (2018) 606–609
Author name / Procedia CIRP 00 (2018) 000–000
thought of as advantageous during the machining of gray cast
iron, thus, the use of a set of specially manufactured bcBN tools
were included as part of the current study.
As found by Fiorini and Byrne [12], a tool protection layer,
TPL, could be expected to form on the tool surface while
machining gray cast iron with pcBN tools due to the transfer of
MnS onto the contact surfaces. A tool protection layer, TPL,
sometimes also referred to as a built-up layer, BUL, is a thin,
protective, regenerative layer formed on the surface of the
cutting tool due to its interaction with inclusions in the
workpiece material. The benefits of such a layer on tool
protection during turning have been well clarified, especially
for stainless steels [13-15]. The TPL will act as a protective
layer between the tool and workpiece during machining and
thus decrease the rate of deterioration. A similar phenomenon
has also been observed while machining white cast iron [16]
and Alloy 718 [17] with pcBN tools. Thus, study and
characterization of such protective layer on the worn cutting
tool formed a central part of the current study.
2. Experimental investigation
During this investigation, machining of common gray cast
iron EN-GJL-250 (SS0125) was examined, Fig. 1. The generic
composition of EN-GJL-250 can be found in Table 1 and
selected material properties in Table 2.
Fig. 1. Optical and electron microscopy of EN-GJL-250 material
microstructure, and EDX mapping of non-metallic inclusions.
Table 1. Chemical composition [18].
Material C wt.% Si wt.% Mn wt.% P wt.%
EN-GJL-250 3.2 – 3.5 1.5 – 2.1 0.6 – 0.8 < 0.25
Table 2. Selected material properties [19].
Material Tensile strength [N/mm2] Hardness [HB]
EN-GJL-250 250 - 350 100 - 175
The tests involved binderless, bcBN, tool material [20]
manufactured with two edge preparations; chamfered insert
607
2
RNGN090300S01020 and sharp insert RNGN090300, Fig. 2.
These were compared with a commercial high-cBN tool grade
with CNGX120416T02020 geometry. To establish the original
geometry of the inserts, 3D analysis of the tools in as-supplied
conditions was performed and the edge radius was measured.
The analysis showed that the chamfered bcBN tool had an edge
radius of 13 µm, as compared to the sharp tool, 17 µm, whereas
the pcBN tool was slightly blunter with an edge radius of
approximately 25 µm.
Fig. 2. Tools in as-supplied state; bcBN chamfered (left), bcBN sharp (right)
and commercial pcBN (bottom).
For each tool, longitudinal turning was performed on a
round bar having an active length of 708 mm. Material
restrictions set a limit of approximately 15 000 m of spiral
distance for each test. Following recommendations from the
industry, the cutting data was selected as cutting speed vc =
1300 m/min, feed f = 0.5 mm/rev and depth of cut ap = 0.7 mm.
Measurement of the tool wear was performed continuously
during the machining tests. The tests were interrupted every
2500 m and the complete assembled tool was inspected with
optical microscopy. This ensured maintaining the correct
position for round inserts. Worn tools were cleaned with
alcohol and measured on a Alicona Infinite Focus 3D
microscope. A typical image of the observed tool wear is
shown in Fig. 3.
Fig. 3. Typical wear pattern at the end of a machining test.
The wear surface generally consisted of uniform wear land
(region B) and a notch wear (region A) in the region of surface
generation. The microscopy also showed that some part of the
S wt.% wear land is covered with an adhesion layer strongly attached
< 0.15 to the tools. This was further confirmed through SEM
observations, Fig. 4. This makes the measured flank wear value
VB uncertain as the real wear land is partly invisible. As a mean
for confirming the extent of tool wear, etching was performed
on all tools after the measurement and microscopy. The etchant
used was Keller’s etchant: 30 ml water; 2 ml HF; 3 ml HCl, and
2 ml HNO3. The etching was done for 4 minutes in an
ultrasonically stirred bath.
608 Fredrik Schultheiss et al. / Procedia CIRP 77 (2018) 606–609
Author name / Procedia CIRP 00 (2018) 000–000
Fig. 4. BSE image of the tool wear pattern on a pcBN tool.
Both the measurement of wear land and 3D microscopy
were repeated after the etching. Fig. 5 shows the development
of the uniform (region B) tool wear during machining. A rapid
progression (approx. 100 µm) of visible flank wear was
observed during the first pass, gradually increasing during
machining. The slope in the wear curves is essentially similar
for all tools. The sharp bcBN tool had a much larger notch wear
(region A) as seen from Fig. 5, distinguishing it from the other
tools tested. Despite these differences, only minor variations of
the cutting forces were observed.
Fig. 5. Progression of uniform flank wear (left) and notch wear (right) for all
tools.
In general, the worn tools were found to have a rather small
wear land but relatively big edge radius as compared to their
unworn geometry which indicates that edge rounding may be a
main parameter for analyzing tool deterioration. Sharp bcBN
tool had the smallest edge rounding both in the notch wear
region, region A, and uniform wear region, region B, Fig. 6.
Fig. 6. Edge radius for etched tools in the notch wear region, region A, and
uniform wear region, region B.
3
Adhered material was found on both the rake and clearance
face of the cutting tools used, Fig. 7.a. During this study, more
in-depth analysis of the adhered material was performed on the
commercially available pcBN tools while limited evaluation
was performed of the bcBN due to the observation of similar
types of adhered material on all tool grades.
Fig. 7. (a) Adhered material on the rake and clearance face of a pcBN cutting
tool. (b) Closeup view of the worn edge radius.
In the chamfer region of the rake face the adherent layer has
a predominant presence of Mn and S, and minor amounts of Si,
Al and O, Fig. 8. Most likely, transfer of MnS and Al2O3, Fig.
1, occurs. Further away from the edge radius the adhered
material contains predominantly Si, O, and minor Fe, Mn and
S, indicating formation of SiO2 with minor amounts of MnS
and FexOy.
Fig. 8. Adhered material on the rake face chamfer region and EDX mapping.
Adhered material on the rake face will decrease the wear
rate by acting as a diffusion barrier – tool protection layer –
thus preventing crater wear. However, the conventional tool
wear criterion is related to the development of flank wear, VB.
Thus, presence of adhered material on the clearance face could
generally be expected to have a more pronounced influence on
tool life. SEM microscopy also shows that no adhered material
is found on the edge radius, Fig. 7.b, thus potentially affecting
accelerated wear and related edge rounding.
The tool protection layer on the clearance face was found to
consist of essentially the same elements as found on the rake
face, i.e. Mn, S, Si, Al and O, although with a somewhat lesser
amount of Mn and S, Fig. 9.
Fig. 9. Adhered material on the wear land and respective EDX mapping.
 Fredrik Schultheiss et al. / Procedia CIRP 77 (2018) 606–609
Author name / Procedia CIRP 00 (2018) 000–000
Cross sectional transmission electron microscopy (TEM) on
the wear land (prepared by focused ion beam) was performed
to explicitly identify the phase composition of the adhered
material. Fig. 10 shows high-angle annular dark-field scanning
transmission electron microscopy (HAADF-STEM) image and
respective XEDS composition maps. These data indicate the
diffusional attack of Fe on cubic boron nitride and
insignificant, if any, effect on the AlN and AlB2 binder. Worn
pcBN material is covered by a continuous tool protection layer
consisting of MnS, SiO2 and Al2O3. Nanometeric layer of Ce
and La was found on the interface between pcBN and MnS.
Fig. 10. Cross sectional HAADF-SEM and XEDS of wear land sample.
Selected area electron diffraction (SAED) on the TPL shows
that SiO2, MnS and Al2O3 are crystalline, the later two having
similar crystallographic structure, Fig. 11.
Fig. 11. SAED patterns of MnS and Al2O3 adhered to the wear land.
3. Conclusions
Based on the obtained results, only minor differences can be
observed between the evaluated tool materials during high-
speed machining of gray cast iron granted that a proper, i.e.
chamfered, tool micro geometry is utilized. For similar micro
geometries, the bcBN tools outperformed the pcBN tool
investigated, especially in terms of edge radius blunting.
The presence of tool protection layer was found on both the
bcBN and pcBN cutting tools under the current investigation.
In the chamfer region TPL predominantly consists of MnS with
a minor amount of SiO2 and Al2O3 transferred from the cast iron
onto the tool. Outside the chamfer, the TPL instead primarily
consists of SiO2 with minor amounts of MnS and FexOy, as a
result of workpiece oxidation and deposition of such oxides
onto the tool. The presence of the TPL, having similar
composition, yet with slightly lower concentration of MnS, was
also found on the wear land. Edge radius region, however, was
devoid of the tool protection layer, thus potentially explaining
intensive edge wear and rounding.
609
4
Acknowledgment
The authors wish to acknowledge the invaluable
contributions made by the “Competitive gray cast iron for
sustainable development” research project funded by Vinnova.
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