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Mohan Ty 2015
Mohan Ty 2015
To cite this article: A. Mohanty, S. Gangopadhyay & A. Thakur (2015): On Applicability of Multilayer Coated Tool in Dry
Machining of Aerospace Grade Stainless Steel, Materials and Manufacturing Processes, DOI: 10.1080/10426914.2015.1070413
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On applicability of multilayer coated tool in dry machining of aerospace grade
stainless steel
Abstract
The present research work has been undertaken with a view to investigate the influence
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machining characteristics such as chip morphology, tool wear, cutting temperature and
machined surface roughness during dry turning of 17-4 PH stainless steel. In order to
understand the effectiveness of CVD multilayer coated tool a comparison has been
carried out with that of uncoated carbide insert. The surface roughness and cutting
temperature obtained during machining with CVD multilayer coated tool was higher than
that of uncoated carbide insert at all cutting velocity. However, the results clearly
indicated that CVD multilayer coated tool played a significant role in restricting various
modes of tool failure and reducing chip deformation compared to its uncoated
counterpart. Adhesion and abrasion were found to be dominating wear mechanism with
flank wear, plastic deformation and catastrophic failure being major tool wear modes.
INTRODUCTION
1
17-4 PH stainless steel is a martensitic precipitation hardenable (PH) stainless steel with a
transforms to lath martensitic structure when brought down to room temperature with a
high cooling rate. This grade of PH stainless steel contains around 17 % of chromium and
4% of nickel as its major constituent elements along with small content of copper as its
precipitates in its structure [1]. The perfect combination of properties such as high tensile
and fatigue strength, good toughness, high hardness, better weldability and formability
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along with excellent resistance to corrosion up to a temperature of 316 °C [2] makes them
attractive choice for aerospace applications. 17-4 PH SS has a good potential to replace
titanium alloys in certain applications for saving material cost. It is used to manufacture
heavy load components such as fasteners, valves, gears, aircraft fittings, coupling,
chemical processing components, hydraulic actuators, rocket & missile components, jet
engines, parts of nuclear reactor, pump shafts, wear rings, valve stems and braces, the
Cutting tools often need to have dual properties. The surface of tool needs to have enough
surface hardness, low coefficient of friction, high wear resistance and chemical inertness,
whereas the core of tool should possess good strength, hot hardness, toughness and high
thermal conductivity. Cutting tool must have collaborative properties both at surface and
core, but it is difficult to have required functionality in one single component. Hence, the
coatings are deposited on surface of tool to achieve desired properties. 17-4 PH stainless
steel can be termed under hard-to-cut material due to its high ductility and low thermal
conductivity. Work hardening, control of chip, chip breakage, built-up edge (BUE)
2
formation, abrasive wear and edge chipping of cutting tool are some of the issues which
impair the machinability of 17-4 PH martensitic stainless steel. The anti-friction property,
hardness, chemical inertness and thermal stability of coated tools often makes them best
choice for machining such category of hard-to-cut materials. Various coatings such as
TiN, TiC, TiAlN, TiCN and Al2O3 have been deposited over cutting tools with different
of stainless steel, few research attempts have been made. Ti[C, N] mixed alumina inserts
exhibited better resistance to both flank and crater wear than that of SiC whisker
reinforced alumina inserts while machining martensitic SS of grade AISI 410. Poor wear
resistance of SiC whisker reinforced alumina inserts can be attributed to higher solubility
of silicon towards iron at high temperature [7]. In another study, same researchers [8]
demonstrated improvement in tool life with the addition of zirconia into Ti[C, N] mixed
alumina when compared to the other two tools i.e. Ti[C, N] mixed alumina and SiC
whisker reinforced alumina inserts. Chipping/fracture of principal cutting edge and nose
wear were prominent modes of tool failure during dry and wet machining of martensitic
stainless steel. Separate grades of coated carbide tools such as CVD multilayer (Ti(C,
N)/TiC/Al2O3) and PVD single layer (TiN) coated insert were used during machining of
martensitic stainless steel in order to investigate effect of both substrate and coating
materials. CVD multilayer coated tool outperformed than PVD single layer coated tool
owing to its sharp cutting edge, reduced hardness caused by high cutting temperature,
3
pitting corrosion of the TiN coating [9]. Flank wear, crater wear and notch wear were
major modes of tool failure during machining of various grades of martensitic stainless
steel with different coated tools as observed by various researchers [9-11]. Taguchi
methodology was used for design of experiment during turning of 17-4 PH stainless steel.
Back propagation neural (BPN) network has been used to predict average flank wear.
Genetic algorithm (GA) was later used to determine optimal cutting parameters to
achieve maximum material removal rate (MMRR) with predicted value of average flank
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Machining of martensitic stainless steel under lower feed rate resulted in better surface
finish which got coarser with increase in the feed rate. The improvement of machined
surface finish with increase in cutting speed was found to be nominal [10]. Better surface
finish was produced at cutting speed (Vc) of 225 m/min with feed rate (f) of 0.125
mm/rev and depth of cut (DOC) of 0.50 mm during dry turning of AISI 440C martensitic
SS with CBN tool [13]. From the experimental results analysed through response surface
methodology (RSM), machined surface roughness of 17-4 PH stainless steel was found to
respond more quickly to changes in the parameters than other grades of steel (ST T1/13W
and ST 12TE). Cutting speed and feed were found to be most significant parameters. Best
surface quality was achieved at high cutting speed of 200 m/min and medium feed rate of
145 mm/min for machining of 17-4 PH stainless steel. At lower cutting speed of 75
m/min, deterioration in surface finish was noted when feed was elevated from 100-200
mm/min [14].
4
From the review of past literature, it is evident that although some research work has
been undertaken on machining of few grades of martensitic stainless steel, in depth study
hardly been reported so far. With 17-4 PH stainless steel being used in several strategic
and also to evaluate the role of coated tool. Therefore, in the current research work, the
turning operation. In order to achieve best utilization of various hard coatings, a coated
tool with multilayer configuration has been preferred. A top layer of ZrCN coating
provides toughness along with anti-friction property, while Al2O3 coating was chosen for
its low thermal conductivity and hot hardness. TiN and TiCN possess excellent hardness
in combination with good anti-friction properties. Machining was carried out under three
variable cutting speeds (100, 140 and 190 m/min) along with machining duration (t) and
wear, chip characteristics (morphology and chip thickness), surface roughness and cutting
tool temperature was evaluated. Constant depth of cut of 0.5 mm and feed rate of 0.2
A round bar of 17-4 PH stainless steel with a dimension of 80 mm diameter and 600 mm
length having the chemical composition as indicated in Table 1 was used for the purpose
of experimentation.
5
A heavy duty lathe (Make: Hindustan Machine Tools (HMT) Ltd., Bangalore, India;
Model: NH26) was used for turning of 17-4 PH stainless steel. Dry turning operation was
performed with three variable cutting speeds (100, 140 and 190 m/min) utilising a
constant feed rate (f) of 0.2 mm/rev and depth of cut of 0.5 mm. The study considered
two types of cutting tools i.e. uncoated cemented carbide insert with ISO P30 grade
(Make: Widia, India) and CVD multilayer coated tool (Make: Widia, India) having
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aspects of machinability of 17-4 PH stainless steel. Designation of both the uncoated and
coated inserts was SCMT 120408 and that of tool holder was SSBCR2020K12.
Each of the experimental runs was carried out for a machining duration of 60 s. Cutting
temperature was measured with the help of K-type thermocouple located at the bottom of
the tool holder approximately at a distance of 3 mm from shim as can be seen in Fig. 1.
The chips formed during machining were collected for further analysis. Tool wear of
each insert under different machining condition was also measured with a stereo zoom
optical microscope (Make: Radical Instruments). Average flank wear was considered as a
measure of tool wear. Machined surface roughness was determined with surface
profilometer (Make:Taylor Hobson, Model: Surtronic 3+). Chip thickness was measured
using a pointed anvil micrometer. For better statistical accuracy, surface roughness and
chip thickness were measured at five different locations. The mean of all the values was
6
In order to identify various phases of uncoated and CVD multilayer coated tool X-ray
diffraction (XRD) (XPert PW3040/00; PANalytical) was carried out. Also Scanning
dispersive spectroscopy (EDS) by X-ray was utilized to characterize both the cutting
The current study investigated effect of cutting speed, CVD multilayer coating and
tool wear, chip characteristics (chip morphology and chip thickness), machined surface
roughness and cutting tool temperature. This has been discussed as follows:
CHARACTERIZATION OF TOOL
Characterization of uncoated and CVD multi-layer coated tool were carried out using
SEM and EDS. Fig. 2 depicts SEM micrographs of surface morphology of both types of
cutting tool along with EDS spectra. Presence of alloying elements such as Ti, Nb, Ta is
indicative of ISO P grade uncoated cemented carbide tool (Fig. 2a). The top layer of
coated tool being ZrCN, the EDS spectra also correspond to the same as indicated in Fig.
2b.
The cutting tools were further characterized with XRD to confirm different phases
present in the cutting tools. The XRD spectra (Fig. 3a) revealed presence of tungsten
carbide (WC), Co, NbC, TiC and TaC phases as main constituents of ISO P grade
7
uncoated cemented carbide. It is also quite evident from the XRD spectra (Fig. 3b) of
CVD multilayer coated tool that it consists of TiN, Al2O3, TiCN and ZrCN coated layers
Further the EDS dot mapping of the cross-section of the CVD multilayer coated tool
ascertained the true composition of the tool as shown in Fig. 4. The top layer consists of
ZrCN coating followed by thin layer of Al2O3, TiCN and TiN respectively. The bottom
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most layer is of WC-based substrate upon which coating deposition has been carried out.
TOOL WEAR
In the present study, different modes of tool wear during machining of 17-4 PH stainless
steel have been investigated. Fig. 5 depicts the condition of flank surface for both
uncoated and CVD multi-layer coated carbide inserts showing the extent of flank wear
when machining 17-4 PH stainless steel at a constant feed rate of 0.2 mm/rev and for
varying cutting speeds. A variation in the cutting speed may prompt a modification in the
strain hardening of chip, rise in temperature at cutting zone accompanied with increase in
the tool wear rate [15]. Flank wear is usually characterised by abrasive grooves and
parallel ridges on flank face of tool and caused due to frictional rubbing between flank
and machined surface. Fig. 5 shows presence of parallel ridges on flank surface of both
uncoated and CVD coated tool, evidence of abrasion wear during machining. As
observed from Fig. 5, abrasive marks are present on flank surface of both uncoated and
coated tools. These abrasive marks are due to the presence of hard particles primarily
8
During machining, these abrasive particles are either dragged along the direction of chip
flow or freshly generated cutting surface, subsequently abrading the surface in contact.
Abrasive marks were more prominent at flank surface of uncoated carbide tool as
layers of hard coatings. The abrasive marks on flank of uncoated tool intensified with
both increase in machining duration and rise of cutting speed, as observed from Fig. 5.
Uncoated tool developed slight DOC notch wear when machining 17-4 PH SS at 100
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m/min cutting speed and after machining duration of 240 s. Capability of the coated tool
to restrict the formation of notch can be explained by superior edge strength of CVD
multilayer coated tool due to its higher edge radius [16, 17]. For uncoated carbide inserts,
significant damage of nose was noted at cutting speeds of 140 and 190 m/min. Severe
nose wear for uncoated tool can be clearly depicted in Fig. 6. The uncoated tool can be
machining duration at high cutting speed i.e. 190 m/min, whereas tool failure occurred
after 180 s of machining with a cutting speed of 140 m/min. Occurrence of nose wear can
be attributed to high heat generation at the cutting region because of high thermal and
Excellent resistance of coated tool (Fig. 5) for nose wear can be explained to higher
chemical inertness and thermal stability including hot hardness of Al2O3 coating of CVD
multilayer coated carbide insert [18-23]. Fig. 7 shows SEM images of rake surface along
with different modes of crater wear for uncoated and coated carbide inserts. Uncoated
tool suffered from deep crater, DOC notch wear and severe nose chipping. However, the
cutting edge of multilayer coated tool was intact due to ability of to maintain sufficient
9
edge strength, although some material adhesion and coating delamination could be
detected.
Fig. 8 shows the variation of flank wear with progression of machining for variable
cutting speeds during machining of 17-4 PH stainless steel with uncoated and CVD
multilayer coated carbide inserts. It can be deduced from the figure that rate of flank wear
increased with elevation of cutting speed for both types of cutting tools. The generation
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softening of the tool and consequently wearing at faster rate than machining at the lower
cutting velocity. Influence of increase in cutting speed on growth of flank wear was more
Fig. 9 demonstrates progression of nose wear with machining under different cutting
speeds for both uncoated and coated tools. Similar observation with respect to the effect
of cutting speed on flank wear has been noted for nose wear, too. However, nose wear
was found to be more severe than that of the flank wear for both types of tool.
Fig. 10 illustrates SEM images along with EDS spectra of the rake surface of uncoated
and CVD multilayer coated tool at high cutting speed of 190 m/min. Presence of
significant amount of Fe, a major constituent of 17-4 PH stainless steel, as observed from
EDS spectra shown in Fig. 10, clearly signifies material transfer to the rake surface of
both uncoated and coated tools. Although EDS spectrum of the rake surface of coated
tool shows presence of some amount of workpiece material, the coating layer still
10
remained intact during machining as evidenced by the presence coating materials such as
Zr and Al. Hence, it clearly establishes the superiority of CVD multilayer coating in
restricting different modes of tool wear during machining of 17-4 PH stainless steel.
CHIP MORPHOLOGY
Macro morphology of chips after machining 17-4 PH stainless steel using uncoated and
CVD multilayer coated tool with progression of machining and for variable cutting
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The type or form of the chip in the current study has been classified according to ISO
3685-1977 (E). The chips obtained under present machining condition for both types of
tool are continuous and mostly snarled type with few being spiral and tubular type. The
long continuous type of chips is typically obtained during machining of ductile materials.
Hence, high ductility characteristics of 17-4 PH SS with low depth of cut (0.5 mm)
during machining can be attributed to formation of such type of chips. Chip formation in
metal cutting is due to shearing and tearing mechanism. Higher toughness of ductile
materials causes the energy required for shearing and tearing action to be dissipated into
the material, thus maintaining the continuity of the chip which results in generation of
continuous chip. It was found that snarled types of chip were more prominent in all the
cases. There was hardly any influence of cutting speed or tool coating on macro
morphology of chips under the given cutting condition. However, with continuation of
machining and tool approaching towards failure, formation of long but broken tubular
type chip was more dominant as evident from Fig. 11. Formation of crater on rake
11
surface acts as a groove type chip breaker and it increases the breakability of continuous
chip. Growth of tool wear also leads to modification of cutting edge geometry (making
rake angle more negative) which in turn is responsible of chip curling and hence
formation of tubular type of chip. The continuous and snarled types of chips are not
suitable during machining operation as it may have disposable problem harming the
operator and interfere with already machined surface deteriorating its finish. Use of
higher depth of cut along with integrated chip breaker would be beneficial in getting rid
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Light golden chips were obtained during machining with uncoated carbide inserts during
initial stage of machining duration of 60 and 120 s for all cutting speeds. This can be
ascribed to the high frictional force along with greater rate of tool wear for uncoated
carbide inserts. This resulted in generation of high amount of heat at chip-tool interface
with most of heat being carried away by the chip during machining and subsequent
oxidation of chips. While the anti-fiction property of the CVD multilayer coated tool due
to presence of ZrCN and TiN coating prevented large heat generation at the chip-tool
interface. Hence the chips obtained were of similar colour that of 17-4 PH stainless steel
CHIP THICKNESS
chip thickness. Variation of chip thickness with progression of machining for variable
cutting speeds at constant feed rate when machining 17- 4 PH stainless steel with
12
uncoated and CVD multi-layer coated carbide insert is illustrated in Fig. 12. It is evident
from the graph that CVD multi-layer coated tool helped in significant reduction of chip
For the uncoated carbide inserts, the predominant effect of tool wear led to higher chip
deformation with progression of machining duration. The chip thickness for uncoated
tool increased with increase in the cutting velocity which can be attributed to the increase
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in the tool wear with cutting speed. However, machining 17-4 PH stainless steel with
CVD coated tool resulted in significant decrease in the chip thickness with increase in the
cutting velocity due to decrease in the dynamic friction at higher cutting velocity. The
decrease in the friction with rise in cutting speed is due increase of temperature at chip-
Chip thickness for the uncoated tool increased with progression of machining. This is
particularly due to increase in tool wear with machining duration. But for the CVD
multilayer coated tool, there was initial decrease in the chip thickness with machining
duration which can be explained by removal of built-up edge (BUE) formed at early stage
of machining and simultaneously gradual exposure of anti-friction layers i.e. TiN and
TiCN. The later increase in the chip thickness can be attributed to dominant effect of tool
SURFACE ROUGHNESS
13
Fluctuation of surface roughness obtained under constant feed rate of 0.2 mm/rev and
variable cutting speeds with progression of machining when machining 17-4 PH stainless
steel with uncoated and coated carbide inserts is demonstrated by Fig. 13. Surface
roughness was found to be directly proportional to cutting speed for both types of tool.
more severe tool wear which was responsible for poor surface quality [26].
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Surface roughness obtained during machining with CVD multilayer coated tool was
higher than that of uncoated carbide insert in the entire of cutting speeds. This might be
attributed to higher surface roughness of CVD multilayer coated carbide insert compared
to its uncoated counterpart. The increased edge radius of the CVD multilayer coated tool
might have also contributed to higher surface roughness during machining. Similar
observation was also reported by other researchers [16, 17, 27]. With progression of
machining, there was not much variation in the value of surface roughness for both
uncoated and coated tools for low (Vc =100 m/min) and medium (Vc = 140 m/min)
cutting velocity. However, there was increment of surface roughness with machining
duration at higher cutting velocity of 190 m/min when machining with CVD multilayer
coated tool.
CUTTING TEMPERATURE
Owing to low thermal conductivity of 17-4 PH stainless steel generation for cutting
temperature is a critical issue and hence should be studied. The temperature of the CVD
multilayer coated tool was found to be higher than that of uncoated carbide inserts for
14
machining condition as can be observed form Fig. 14. Thermal properties of the cutting
and mechanical properties of the cutting tool with respect to machinability aspects
[5].The thermal conductivity of the uncoated carbide tool is higher than CVD multi-layer
coated tool. Hence, the uncoated tool has greater ability to dissipate heat to the
surrounding so the temperature of the uncoated cutting tool will be less. The lower
thermal conductivity of the insulating coating layers of the coated tool restricted heat to
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dissipate into surrounding; hence temperature of coated cutting tool was high. The cutting
tool temperature increased with both machining duration and increase in the cutting
velocity [28] for both types of the cutting tool. This is due to increase in tool wear with
measured in the current study is the combined effect of heat transferred to the tool and
interface could not be ascertained. Therefore, the effect of CVD multilayer coated tool on
CONCLUSION
The current study investigates the influence of cutting speed and tool coating on various
machinability characteristics during dry turning of 17-4 PH stainless steel. From this
1) Nose wear was found to be prominent tool failure mode for the uncoated carbide
inserts under medium (140 m/min) and high (190 m/min) cutting speed. Flank and nose
wear increased with progression of machining for both uncoated and CVD multilayer
15
coated carbide insert under all cutting speeds. The rate of flank wear for uncoated tool
could also be brought down with the help of CVD multilayer coating.
coated tool exhibited higher cutting temperature than its uncoated counterpart throughout
the experiments.
3) The chips obtained were mostly of long continuous and snarled type. The chips
obtained at initial machining duration were of golden colour which later changed to silver
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colour with progression of machining. CVD multilayer coated tool having anti-friction
property resulted in less chip deformation as compared to uncoated carbide insert. Chip
thickness for both inserts increased with progression of machining, while there was initial
decrease in chip thickness for coated insert. With rise in cutting speed, uncoated tool
exhibited increase in chip thickness, whereas the average value of the chip thickness
4) Surface roughness obtained during machining with CVD multilayer coated tool
The current study, therefore, demonstrated remarkable improvement in tool life and chip
characteristics with the application of CVD multilayer coated tool compared to its
uncoated counterpart in the entire range of cutting speed during dry machining of 17-4
PH stainless steel.
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16
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20
Table 1 Chemical composition of 17-4 PH
Elements C Mn Si P S Cr Ni Cu Nb+Ta
21
Fig. 1 Magnified view of Experimental Setup for Turning of 17-4 PH stainless steel.
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22
Fig. 2 SEM micrographs along with EDS spectra of rake surface of (a) uncoated tool and
23
Fig. 3 XRD spectra for (a) uncoated and (b) coated inserts
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24
Fig. 4 Cross section image of the coated tool along with its EDS dot mapping
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25
Fig. 5 Optical images showing condition of flank surface for uncoated and coated tool.
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26
Fig. 6 Rake surface and nose region of uncoated tool for failure state at cutting speed of
27
Fig. 7 SEM images of the rake surface of the uncoated and coated tool at variable cutting
speed.
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28
Fig. 8 Variation of flank wear with progression of machining duration with variable
cutting speed at feed rate 0.2 mm/rev for (a) Uncoated and (b) Coated tool.
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29
Fig. 9 Variation of nose wear with progression of machining duration with variable
cutting speed at feed rate 0.2 mm/rev for (a) Uncoated and (b) Coated tool.
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30
Fig. 10 SEM micrographs along with EDS spectra of rake surface of (a) uncoated tool
31
Fig. 11 Chip morphology of uncoated and coated cutting tool with progression of
32
Fig. 12 Variation of chip thickness with progression of machining duration with variable
cutting speed at feed rate 0.2 mm/rev for (a) Uncoated and (b) Coated tool.
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33
Fig. 13 Variation of surface roughness with progression of machining duration with
variable cutting speed at feed rate 0.2 mm/rev for (a) Uncoated and (b) Coated tool.
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34
Fig. 14 Variation of cutting temperature with progression of machining duration with
variable cutting speed at feed rate 0.2 mm/rev for (a) Uncoated and (b) Coated tool
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35