Data: 2023/05/22

Ministry of Higher Education

and Scientific Research
University of Karbala
College of Engineering
Mechanical Engineering Dep.

Study the effect of coated and uncoated carbide inserts

on the cutting forces in turning operations
A Thesis Submitted to the Council of the College of
Engineering Department of Mechanical Engineering University
of Kerbala in Partial Fulfillment of the Requirements for the
Bachelor Degree in Mechanical Engineering

Preparation

ENG. Mojtaba Ahmed ENG. Akram Rasem

ENG. Buraq Abbas

Supervisors

L. Basim Salih A.S. Esraa Ibrahim

 ‫ج‬ ‫هْ َ َ ه ه ْ َْ َ ََ‬ ‫َ َه‬ ‫ه‬ ‫َ َْ‬
‫}يرفعِ الل الذِين آمنوا مِنكم والذِين أوتوا العِلم درجات‬
‫َ ه َ ََْه َ َ ر‬
‫والله بِما تعملون خبِي{‬
‫َ َ َ ه َ ُّ َ‬
‫صدق الل العلِي العظيم‬
‫سورة المجادلة (‪)11‬‬
 ‫اهداء‬

‫الحمد هلل الذي بنعمته تتم الصالحات تم انهاء مشروع تخرجنا‬

‫بنجاح نهدي تخرجنا الى معلم البشرية األول محمد صلى هللا‬

‫عليه وآله وسلم والى سيدنا صاحب الزمان عجل هللا تعالى‬

‫فرجه‪ .‬الى سيدة تحت أقدامها الجنة (أمي) الى رجل أفنى‬

‫حياته من أجلنا (أبي) الى من تقف الكلمات حائرة أمام فضلهم‬

‫ومساعدتهم أساتذتنا األفاضل اليكم جميعا ً ننحني ونقدم ثمرة‬

‫سنواتنا الدراسية سائلين المولى عز وجل أن ينفع به وأن‬

‫يجعله لوجهه الكريم‪.‬‬

 ABSTRACT
Cutting force is very important factor to ensuring the optimization
of metal cutting. The present work studies the influence of three variables
(cutting speed, feed rate, and depth of cut) on the cutting force components
in orthogonal turning process using uncoated and variation-coated carbide;
titanium carbide (TIC), titanium nitride (TIN), titanium carbonate (TINC),
aluminum oxide (Al2O3) inserts when machining AISI 1045 alloy steel.
The cutting force was measured simultaneously, using the special FEA
software (DEFORM-2D). Cutting conditions were selected to be five
different cutting speeds (31.5, 49.6, 88.2, 126, and 157.5) m/min, five
different feed rates (0.05, 0.1, 0.15, 0.2, and 0.25) mm/rev. and at width of
cut (1.0 mm).

The results showed that the average forces obtained using the
uncoated carbide tool are higher than those obtained using the coated
carbide tools under the same experimental conditions. The Al2O3 coating
was the best in producing the lowest cutting force in both tangential and
feed forces and at a cutting speed of (157.5) m/min with a feed rate of 0.05
mm/rev where the tangential cutting force (Ft) (115N) and the feed force
(Ff) (61N),While the values of the cutting forces for the rest of the coatings
were gradually from the highest values of the cutting forces when using the
TIN coating (Ft = 125N, Ff = 69N), followed by TICN (Ft = 121N, Ff =
66N) and then TIC (Ft = 117N, Ff = 64N) at cutting speed of (157.5)
m/min and feed rate of (0.05) mm/rev.

1
1.1. Introduction

Machining is a versatile shaping process of major importance for

component manufacturing. The importance of machining in modern
automated manufacturing systems has in fact increased due to the
significant increases in the production times and the need to offset the high
capital investment in these modern systems. The need for improving the
technological performance of machining operations as assessed by the
forces, power, tool-life and surface finish has long been recognized to
increase the economic performance of the machining operations. As such,
continual improvements in the technological performance of machining
operations have been sought through research and development including
new and more wear resistant tool materials as well as new geometrical tool
designs. One of the important cutting tool improvement in recent years has
been the introduction of hard surface coatings on the substrates such as
carbides. Hard coatings such as (TiN, TiC and Al2O3) have been used and
claimed to significantly improve the tool-life. It has also been claimed that
such coatings reduce the forces and power due to lower friction coefficients
on the rake face. [1].

1.2. Theory of metal cutting: -

Metal cutting is one of the most common and most economical

ways to produce components in engineering. the mechanics of the metal
cutting process is very important, because the chip forming process
depends on the cutting forces, energy consumption and the amount of heat
generated, the precision of the machined components, its surface quality,
the operating conditions of the machine and tools, and so on [2].

Machining is one or more processes in which a piece of raw material

is worked by controlled material-removal operations in order to reach the

2
desired design. These operations are often used for elaborating difficult
geometries and obtaining final shapes. Most of manufacturing processes
are followed by metal-removing operations in order to get the desired final
shape, dimension or quality. These processes are also commonly known as
Subtractive Manufacturing. The machining operations can be classified
under two major categories: cutting and grinding processes. The most
common cutting operations are turning, milling, and drilling followed by
special operations such as boring, broaching, hobing, shaping, and form
cutting. All metal cutting operations use the same general mechanics, the
material is removed by a cutting edge, but with different geometries and
application. [3].

1.3. Type of metal Cutting

1.3.1. Orthogonal Cutting

The material is removed by the cutting tool edge precisely located

perpendicular to the work piece surface. Therefore, in this shaping process
the tool’s cutting edge is also perpendicular to the direction of the cutting
velocity (Vc). To understand the cutting process, some parameters have to
be defined. As an introduction, width of cut (w) and depth of cut, (Uncut
chip) thickness represented by (𝑡𝑜 ) in (Fig. 1.1) are two properties that are
going to describe the dimension of the metal chip removed.

Fig 1.1. Three dimensional orthogonal cutting representation

3
 In cutting operations it is known that the chip formed flow off as
series of parallel plates sliding relative to each other. As the chip is formed
along the shear plane, the uncut chip thickness increases to the deformed
chip thickness (t c ), the relation between them is called the chip
compression ratio(rc ). Related as follows

to
rc = (1)
tc

The cutting is assumed to be uniform and the cutting forces are going to be
found in the directions of the velocity and the feed rate (f). These two forces
are called Tangential Force (Ft ) and Feed force (Ff ). Only orthogonal two-
dimensional cut is being explained by now, in oblique cutting a third force
appears due to the inclination angle (i) of the cutting edge. This force acts
in the radial direction, Radial Force (Fr ). In the figures below the
deformation geometry caused by the removal operation and the forces
generated in it are shown. In this simple explanation, it is assumed that the
cutting edge is sharped and without nose radius, so the deformation
produced in the shear zone is thin enough as in (fig 1.2).

Fig 1.2. Orthogonal cutting zones

To describe in a better way, the geometry, some parameters are
explained. The shear angle (Φc ) is defined as the deviation between the

4
share plane and the direction of the cutting speed. Also, the rake angle (αr )
of the tool is shown. It is also known that the normal stress (σs ) and the
shear stress (τs ) are considered constant. Force equilibrium is found as the
relation between forces. The resultant cutting force is the formed from the
tangential cutting force (Ft ) and the Feed force (Ff ), as presented by

Fc = √ Ft 2 + Ff 2 (2)

Feed force (Ff ) is found in the direction of the uncut chip thickness and
Tangential force (Ft ) on the direction of the Cutting Velocity (Vc ). As the
equilibrium theory proves, the tool receives the same forces in equal
amplitude but opposite direction. the velocity diagram (see Fig.1.3) also
called shear strain triangle, is used to derive strain equation.

Fig 1.3. Mechanics of orthogonal cutting

However, it has to be highlighted that not all forces can be measured

directly. In fact, only the forces acting on the tool can be measured directly.
Tangential cutting force (Ft ) and Feed force (Ff ) (also called Thrust force)

5
As in (fig.1.4). The rest of forces are the ones acting in the chip and for
calculating them, the relationship between them must be known.

The Shear force (Fs ) is the force acting in the shear plane and it can
be calculated as

Fs = Fc cos(Φc + β − αr ) (3)

Fig 1.4. Force diagram in orthogonal cutting

Also, there is a Normal force (Fn ) acting on the shear plane and it is
similarly described by the equation

Fn = Fc sin(Φ + β − α) (4)

Two components of the cutting force belonging to the secondary shear zone
are acting directly on the rake face of the tool. The normal force (N) and
the Friction force (Fu ) on the rake face are presented as follows

N = Ft cos(αr ) − Ff sin(αr ) (5)

Fu = Ft sin(αr ) − Ff cos(αr ) (6)

Shear stress (τs ) is the component of stress that is coplanar with the shear
plane surface. As it is assumed, the shear stress is determined as follows
(fig 1.5).

6
 Fig 1.5. Forces acting in the chip
Fs
τs = (7)
As

Where (As ) is the Area of the shear plane and it is determined by

𝑤ℎ
As = (8)
sin Φ

Where (w) is the width of cut and (h) the uncut chip thickness (depth of cut
in turning). In the moment when the shear angle is needed the (rc ) ratio
must

be calculated. The shear angle is found from the geometry as a function of

the rake angle and the chip compression ratio as

rc cos(α)
Φ = tan−1 (9)
1 − sin(α)
As it is known, orthogonal cutting cannot be directly applied to practical
cutting calculations due to numerous facts such as tool geometry, work
piece material or chip breaking grooves. [3].

1.3.2. Oblique cutting

The orthogonal cutting process is the simplest form of the metal

cutting processes. In practice, the cutting process is rarely of the orthogonal
type, although some may approximate to it. Most practical cutting
processes are oblique, i. e. the motion of the tool relative to the work piece

7
is not perpendicular to the cutting edge, but makes an angle with it. The
idea that oblique cutting involved certain additional factors not present in
orthogonal cutting was first revealed by Sellergren in 1896, but since then
relatively little further attention has been given to it [2].

Oblique cutting is a different type of cutting in which the tool’s

cutting edge make an angle (i) with the direction of tool motion. This will
affect the cutting conditions and redirect the cutting forces. It is also known
as 3D cutting because the cutting forces developed during cutting cannot
be represented by 2D coordinate (As in fig 1.6).

Fig 1.6. Geometry of Oblique cutting

In oblique operations, the cutting velocity (Vc) has an oblique or

inclination angle (i). Therefore, the directions of shear, friction, chip flow,
and resultant cutting force vectors have components in the three Cartesian
coordinates (x, y, z). The important planes in oblique cutting are the shear
plane, the rake face, the cut surface (xy), the normal plane and the velocity
plane. It can be considered that the mechanics of oblique cutting in the
normal plane are equivalent to the orthogonal cutting with a projection
depending in the inclination angle (i). Some of the important angles and
forces need to be explained in order to understand then mechanics of this

8
operations. The normal shear angle (φn) is the angle between the shear and
(xy) planes. In the other hand, the oblique shear angle (φi) is the angle
made between the shear velocity and the vector normal to the cutting plane
on the normal plane. The sheared chips flow over the rake face with an
angle called chip flow angle (η), normal to the cutting edge and its known
to lie on the normal plane (Pn). The normal rake angle (αn) is the angle
between the (Z) axis and the normal vector on the rake face. After the
introduction of the geometrical angles needed, forces must be introduced.

There is an existent friction force created in the operation and it has

the same direction as the chip flow. The resultant cutting force created in
these operations is generated from the friction force on the rake face (Fu)
and the normal force on the rake (N) with a friction angle between them
(β). The resultant force vector has a projection angle (θ) with the normal
plane (Pn), which at the same time has an angle of (β+α) with the normal
force. There have been numerous proposed solutions based on empirical
results in chip flow direction and other empirical assumptions. In this
paragraph, the focus is on the prediction of the shear direction based on the
law of mechanics. Therefore, a summary of the most important principles
is introduced. [3].

1.4. Measurement of cutting force

The existence of some physical variables like force, temperature etc.

and its magnitude or strength cannot be detected or quantified directly but
can be so through their effect only. For example, a force which can neither
be seen nor be gripped but can be detected and also quantified respectively
by its effect and the amount of those effects (on some material) like elastic
deflection, deformation, pressure, strain etc. These effects, called signals,
often need proper conditioning for easy, accurate and reliable detection and

9
measurement. The basic principle and general method of measurement is
schematically (shown in Fig.1.7)

Fig. 1.7. General principle of measurement.

The measurement process is comprised of three stages:

1. The target physical variable (say force) is converted proportionally

into another suitable variable (say voltage) called signal, by using
appropriate sensor or transducer.
2. The feeble and noisy signal is amplified, filtered, rectified (if
necessary) and stabilized for convenience and accuracy of
measurement.
3. where the conditioned signal (say voltage) is quantitatively
determined and recorded by using some read out unit like
galvanometer, oscilloscope, recorder or computer. [4]

10
1.4.1. Strain Gauge Dynamometer

A strain gauge is a device initially used to measure the strain of an object.

It can also be used to measure the forces applied on a structural body by
making use of Hooke's law. It consists of a tiny electric wire arranged in a
defined pattern on the structure of the machine. When the structure deforms
in response to the load the wire is stretched, the resistance of the metallic
wire changes changing the voltage sensed across it. With proper calibration
it is then possible to relate this voltage to displacement and when the
stiffness of the structure is known force can be estimated. Since the force
measurement in this device relies on member deflection, it necessitates that
this deflection be relatively high (several micrometers) for this technique
to be feasible. Depending on the range required this can add undesirable
compliance to the system. (Fig.1.8) shows the principle of force
measurement by measuring strain, which would be proportional to the
magnitude of the force (Fc).

Fc

Fig. 1.8. Measuring cutting forces by strain gauges

The strain induced by the force changes the electrical resistance (R),
of the strain gauges which are firmly pasted on the surface of the tool-
holding beam. The change in resistance of the gauges connected in a

11
Wheatstone bridge produces voltage output ΔV, through a strain measuring
bridge (SMB) (as indicated in fig.1.9). Out of the four gauges, R1, R2, R3

and R4, where R1, R3 are put in tension and R2, R4 are put in compression

(as shown in fig.1.9) [4].

Fig. 1.9. Force measurement by strain gauge based transducer.

1.4.2. Mechanical dynamometers

They often make use of sensitive dial indicators for direct

measurement of tool forces as the dial indicators are calibrated to show
directly the magnitude of tool forces corresponding to the deflections
caused in the tool holder by these forces; for example, the cutting force (Ft)
(Fig. 1.8) tends to deflect the tool and tool holder downwards, axial force
(Fa) acts along the axis of workpiece (opposite to feed) and radial force

12
(Fr) will push the tool away from workpiece and may cause chatter. A
typical two-dimensional dial indicator type mechanical dynamometer is
shown in (Fig. 1.10) to measure force (Ft and Fa). [5]

Fig. 1.10. A two dimensional dial indicator type mechanical force dynamometer

1.5. Coatings

Machining efficiency is improved by reducing the machining time

with high speed machining. But the softening temperature and the chemical
stability of the tool material limits the cutting speed. When cutting ferrous
and hard to machine materials such as steels, cast iron and super alloys,
softening temperature and the chemical stability of the tool material limits
the cutting speed. Therefore, it is necessary for tool materials to possess
good high-temperature mechanical properties and sufficient inertness.
While many ceramic materials such as TiC, Al2O3 and TiN possess high
temperature strength, they have lower fracture toughness than that of
conventional tool materials such as high-speed steels and cemented
tungsten carbides. The machining of hard and chemically
reactive materials at higher speeds is improved by depositing single and

13
multi-layer coatings on conventional tool materials to combine the
beneficial properties of ceramics and traditional tool materials.

Coatings are diffusion barriers, they prevent the interaction between

chip formed during the machining and the cutting material itself. The
compounds which make up the coatings used are extremely hard and so
they are very abrasion resistant. Typical constituents of coating are
Titanium Carbide (TiC), Titanium Nitride (TiN), Titanium Carbonitride
(TiCN) and Aluminium oxide (Al2O3). All these compounds have low
solubility in iron and they enable inserts to cut at much higher rate. [6].

1.5.1. Types of Coating Technology

Surface coating of tribological applications is associated with

deposition temperatures ranging from room temperature to over 1000°C.
The coating thickness ranges from microns to several
millimetres. Typically, the atomistic methods produce the thinnest
coatings. Some methods involve high deposition temperatures that may
give undesired phase transformations, softening or shape changes of the
coated component. An important benefit of PVD and CVD processes is the
high flexibility as to composition and structure of the coatings, and these
processes are today successfully utilized to coat a large variety of
mechanical components. [6].

1.5.1.1. CVD (Chemical Vapour Deposition)

CVD method deposits thin films on the cutting tools through various
chemical reactions. CVD coated cemented carbides have been a huge
success since their introduction in the late 1960’s. Since then, chemical
vapour deposition technologies have advanced from single layer to multi-
layer versions combining TiN, TiCN, TiC and Al2O3. Modern CVD
coatings combine high temperature and medium temperature processes in

14
complex cycles that produce excellent wear resistant coatings with a
total thickness of 4-20 μm. However, the high deposition temperature
(950-1059°C) during CVD results in diffusion of chemical elements from
the carbide substrate to the coating during growth. The main effect is an
embrittlement of the coating edge. In addition, the chemistry of the CVD
process results in more rapid growth at the cutting edge resulting in an even
coating thickness. Therefore, there was a strong driving force to find
coatings that could be deposited at lower temperatures in order to
allow tools with sharper edges to be coated without any embrittlement
effect. The solution is PVD where deposition temperature can be kept at
around 500°C. [6].

1.5.1.2. PVD (Physical Vapour Deposition)

PVD method deposits thin films on the cutting tools through

physical techniques, mainly sputtering and evaporation. PVD coatings,
with deposition temperatures of 400-600°C, are gaining greater
acceptance in the market place. Over the last decade, they have been
successfully applied to carbide metal cutting inserts. They offer
performance advantage in applications involving interrupted cuts, those
requiring sharp edges, as well as finishing and other applications.
Depending on the intended application, different PVD technologies such
as electron beam evaporation, sputtering and arc evaporation are
used. Improvements in these technologies such as high ionization
magnetron sputtering and new cathodic arc processes have further
improved the performance of PVD coated tools. The metal cutting
performance of PVD coated tools depend strongly on the composition,
microstructure, internal stresses and adhesion of the coating to the
substrate as well as the substrate composition and tool geometry. PVD
process chain includes pre-PVD processes and post PVD-processes. Pre-

15
treatment processes such as plasma etching and chemical etching influence
adhesion, grain growth, stress at substrate surface and coating structure,
whereas post-PVD processes influence smoothness of coating surface and
better chip flow. PVD coatings attribute excellent cutting performance to
cemented carbide inserts. The reason that PVD has more and more taken
over with regards to deposition of many coatings is the advantages that
lower coating temperatures give with regard to micro-toughness. [6].

1.5.2. Layers of coating

1.5.2.1. Single layer coating

The first coating was a single layer of (TiC). (10 to 12) micrometres
thick, which was deposited by a process known as chemical vapour
deposition (CVD) onto a substrate of hard metal. During the
deposition process some carbon was taken up from the surface of the hard
metal as part of coating and this changed the carbon balance at the junction
of the coating and the hard metal substrate. This lowering of the carbon
balance caused the formation of a brittle compound at the interface between
the coating and the substrate and made early coated index able inserts
sensitive to chipping of cutting edge. The next development was to put
down a coating of (TiN) which prevented any decarburising of the hard
metal substrate but the coating which is gold in colour, did not adhere well
to the hard metal base. (TiN) is an even better diffusion barrier than (TiC)
but (TiC) has better abrasion resistance. [6].

1.5.2.2. Multi-layer coatings.

Although single-layer coatings are finding a range of applications in

many sectors of engineering, there are an increasing number of
applications where the properties of a single material are not sufficient.
One way to surmount this problem is to use a multilayer coating that

16
combines the attractive properties of several materials, each chosen to
solve a problem in the application. Multi-layer coatings can consist of as
many as eight layers with in a total thickness of 10 micrometres or less.
Simple examples of this include the use of interfacial bonding layers to
promote adhesion, or thin inert coatings on top of wear resistant layers to
reduce the corrosion of cutting tools. There is, however, mounting
evidence that the multilayer structure produced when many alternating
layers of two materials are deposited can lead to improvements in
performance over a mixed coating (by virtue of the introduction of new
interfaces) even if the two materials do not have specific functional
requirements in the intended application. (As in fig 1.11). [6].

Fig 1.11. Schematic diagram of coatings that used

in cutting tools (a) Single layer (b) Multi-layer

1.6. Finite Element Simulation of Metal Cutting.

Metal cutting researchers focus on determining the best cutting

conditions and tool geometries for process efficiency. Experimental works
are needed to obtain results but they are expensive and time consuming. In
addition to this, simplified analytical methods have limited applications
and they cannot be used for complex cutting processes. At this point
numerical methods become important. In last two decades, Finite Element
Method (FEM) has been most frequently used in metal cutting analysis.

17
Various outputs and characteristics of the metal cutting processes such as
cutting forces, stresses, temperatures, chip shape, etc. can be predicted by
using FEM without doing any experiment. In this chapter, some basic
aspects of finite element simulation of metal cutting are presented. [7].

1.6.1. Model Formulation

Three main formulations are used in finite element simulation of

metal cutting: Lagrangian, Eulerian and Arbitrary Lagrangian-Eulerian
(ALE). [7].

1.6.1.1. Lagrangian

Lagrangian formulation is mainly used in solid mechanic's

problems. Here the FE mesh is attached to work piece material and cover
the whole of the region under analysis. This makes it highly preferable
when unconstrained flow of material is involved. Lagrangian formulation
is broadly used in metal cutting simulation due to ability to determine
geometry of the chip from incipient stage to steady state and this geometry
is a function of cutting parameters, plastic deformation process and
material properties. Therefore, boundaries and shape of the chip do not
have to be known a priori. Besides, chip separation criteria can be defined
to simulate discontinuous chips or material fracture in metal cutting models
which are based on Lagrangian formulation. Although there are many
advantages of Lagrangian formulation, it has also shortcomings. Metal
being cut is exposed severe plastic deformation and it causes distortion of
the elements. Therefore, mesh regeneration is needed. Secondly, chip
separation criteria must be provided. This drawback of formulation can be
eliminated by using an updated Lagrangian formulation with mesh
adaptively or automatic remeshing technique. [7].

18
1.6.1.2. Eulerian

In Eulerian formulation, the FE mesh is spatially fixed and the

material flow through the control volume which eliminates element
distortion during process. Besides, fewer elements required for the
analysis, thereby reducing the computation time. Cutting is simulated from
the steady state and therefore there is no need for separation criteria in
Eulerian based models. The drawback of Eulerian formulation is a need in
determining the boundaries and the shape of the chip prior to the
simulation. Also the chip thickness, the tool-chip contact length and the
contact conditions between tool-chip must be kept constant during analysis
which makes Eulerian formulation does not correspond to the real
deformation process during metal cutting. [7].

1.6.1.3. Arbitrary Lagrangian-Eulerian (ALE)

The best features of Lagrangian and Eulerian formulations have

been combined and called arbitrary Lagrangian-Eulerian (ALE). In ALE
formulation, the FE mesh is neither fixed spatially nor attached to the work
piece material. The mesh follows the material flow and problem is solved
for displacements in Lagrangian step, while the mesh is repositioned and
problem is solved for velocities in Eulerian step. The idea used in metal
cutting simulation is to utilize Eulerian approach for modelling the area
around the tool tip where cutting process occurs. Therefore, severe element
distortion is avoided without using remeshing. Lagrangian approach is
utilized for the unconstrained flow of material at free boundaries.
Furthermore, shape of the chip occurs as a function of plastic deformation
of the material. This approach is (shown in Figure 1.12). [7].

19
 Fig 1.12. Eulerian and Lagrangian boundary conditions in ALE simulation

1.6.2. Meshing

A continuous region is divided discrete region called elements in FE

analysis. This procedure is called discretization or meshing. Initial
designed FE mesh cannot hold its original shape and it is distorted due to
severe plastic deformation during metal cutting or metal forming
processes. The distortion causes convergence rate and numerical errors. To
handle with this problem a new FE mesh must be generated in means of
changing the size and distribution of the mesh. This is called adaptive mesh
procedure. One of adaptive mesh procedure is remeshing technique and it
includes the generation of a completely new FE mesh out of the existing
distorted mesh. Second one is called refinement technique which is based
on increasing the local mesh density by reducing the local element size (as
shown in Figure 1.13)

Fig 1.13. Refinement: (a) Initial local mesh, (b) Reducing element size

20
The last adaptive mesh technique is smoothing which includes reallocating
the nodes to provide better element shapes (as shown in Figure 1.14)

Fig 1.14. Smoothing: (a) Initial local mesh, (b) Reallocating of the nodes

The adaptive mesh procedure decreases solution errors during calculation

therefore it increases the accuracy of the simulation. For these reasons, the
adaptive mesh procedure must be used in FE simulations including severe
plastic deformation such as metal cutting and metal forming. [7]

21
 LITRTURE REVIEW
Metal cutting process forms the basis of the engineering industry and
is involved either directly or indirectly in the manufacture of nearly every
product of our modem civilization. The cutting tool is one of the important
elements in realizing the full potential out of any metal cutting operation
[6]. The requirements of economic competition have stimulated a lot of
research in the field of metal cutting, leading to the creation of several types
of coatings for the number of cuts and comparison of their properties to
obtain the lowest cutting force. One of the most important cutting tool
improvements in recent years has been the introduction of hard surface
coatings on substrates such as carbides. Hard coatings such as
(Titanium Carbide (TiC), Titanium Carbonitride (TiCN), Aluminium
oxide (Al2O3) and Titanium Nitride (TiN)) have been used and have been
claimed to significantly improve tool life, enabling components to be
machined at higher 'economical' speeds. It has also been claimed that such
coatings reduce forces and strength due to the lower coefficients of friction
on the rake face.

A large number of experimental investigations and numerical

simulations have been conducted to understand the effect of coating
materials on and from the cutting forces

J. Wang (2000). investigated the effects of multiple layer hard

surface coatings of cutting tools on cutting forces in steel turning for
different commercially available carbide inserts and tool geometries over
a range of cutting conditions. The machining experiments were conducted
on a Takisawa TSL-1000 lathe turning a CS1020 bright mild steel bar using
Kistler type 9257A three component piezoelectric dynamometer. Three
levels of feed rates (0.13, 0.17and 0.21 mm/rev.) and three levels of depth

22
of cut (0.5, 1.0 and 2.0 mm) were tested under two levels of cutting speed
(108 and 206 m/min). Four different inserts of two different geometries
identified by the types of SCMT and CNMM were selected and mounted
on the SSBCR 2020 k12 and PCLNR 2020 k12 tool holders, which were
supplied by Sandvik Company. For each geometry, uncoated as well as
CVD triple coated inserts with Titanium Carbide (TiC)/ Aluminium oxide
(Al2O3)/Titanium Nitride (TiN), (TiN being the top coating layer) of
totally 8 μm were used. The results showed that the percentage deviations
of the cutting forces with coated and uncoated CNMM type inserts increase
about 7% - 25% when the feed rate changes from (0.13 to 0.21) mm/rev.,
while decrease about 17%-13.6% when the cutting speed increases from
(108 to 206) m/min. The results also showed that the cutting forces of the
SCMT type inserts are smaller than those of the CNMM inserts [1].

M.A. Kamille, M.Y. Noordin (2011) The researcher examined the

impact of cutting tool materials on cutting force. They made a selection of
input materials, tool geometry, and cutting conditions to make the difficult
flipping process to produce better surfaces than milling. The researcher
made an attempt to investigate the effect of cutting tool materials on the
cutting forces (feeding force, thrust force and cutting force) in hard
turnings of AISI D2 cold work tool steel The three cutting force namely
tangential force (Fc), radial force (Fr) and feed force (Ff) were measured
during hard turning of AISI D2 cold work tool steel of 60 HRC. In each
experiment, a fresh cutting tool was used and the experiments were
repeated twice at each cutting condition in order to keep experimental error
at a minimum.

The results showed that Under the same cutting condition there is
force difference between using low CBN content tools coated with TiAlN
and CBN-Low coated with Titanium Nitride (TiN)/ Aluminium oxide

23
(Al2O3)/ Titanium Carbonitride (TiCN). This was the case when turning
with uncoated CBN-High and CBN-High coated with TiN/Al2O3/TiCN.
This can be due to the influence of material composition and thermal
properties of the tool. The material properties of the cutting tools have a
greater influence on the feed force and thrust force than on the principal
force. The radial force was found to become the largest of the three force
components at all cutting conditions. Results also shows that the decreased
of the three component forces by using mixed ceramic (Al2O3+ TiCN)
coated with TiN compared to the CBN cutting tools for all cutting
conditions [8].

Dr. Abdul Karim Jalal, Eng. Karim Abdullah (2012) The

researcher studied the effect of cutting parameters (cutting speed, feed, and
cutting depth) on the turning process applied to C-60 steel using multi-
coated Titanium Nitride (TiN)/ Aluminium oxide (Al2O3)/ Titanium
Carbonitride (TiCN) layers' carbide cutting tools at high cutting speeds.
The effect of cutting parameters on cutting forces, tool wear, and surface
roughness is analyzed.

The results show that the cutting forces have a very strong relationship
with the surface finish and that the increased spindle speeds lead to a much
higher surface finish. It has been observed that the cutting force even in
steady state conditions is affected by many parameters and the variation of
cutting force with time has a peculiar characteristic Reduction in cutting
forces which allow the use of high cutting speeds and feed [9].

K.P. Maity & B.D. Sahoo (2012). The researchers studied the
performance of the Titanium Carbide (TiC) + Titanium Carbonitride
(TiCN) + Aluminium oxide (Al2O3) + Titanium Nitride (TiN) coated
multilayer tool in processing hardened steel (AISI 4340 steel) under high
rotational speed and compared it with the uncoated tool. Also the

24
aluminum has been machined using a CNC lathe. A set of cuts was made
using under different cutting conditions (speed (82, 105, 130, 160 m/min),
feed (0.06, 0.08, 0.12, 0.16 mm/rev) and depth of cut (0.5, 0.4, 0.3, 0.2
mm) and monitor cutting forces, surface finish and tooling.

The results showed that the Coated carbide tools (TiCN +TiC+
TiCN+Al2O3+TiN) performed better than uncoated carbide tools as far as
cutting forces are concerned. For average magnitudes of forces obtained
with uncoated carbide tool were higher than those obtained with coated
carbide tools under experimental conditions, and with cutting speed of 160
m/min had been resulted in optimized value of cutting forces in the
experimental range. Cutting feed has a direct effect on cutting force. As the
feed increases there is a direct increase in the cutting forces and the analysis
of the result revealed that, the optimal combination of low feed rate and
low depth of cut with high cutting speed is beneficial for reducing
machining force. [6].

Sisira Kanta et al (2013). The researchers conducted a study on

MCD, WC, and PCD. They compared Micro-Crystalline diamond (MCD)
tool, uncoated tungsten carbide tool and Polycrystalline Diamond (PCD)
tool during dry rolling of coiled aluminium. A set of key tests such as
surface roughness, cutting force and tool wear, which have been taken into
account for proper comparison of advanced cutting tools, have been carried
out. Cutting forces were measured by a Kistler 3D dynamometer during
the curing process. The tests were conducted with three different speeds
(200, 250, 325 m/min), three feed rates (0.09, 0.12, and 0.18 mm/rev) and
one cutting depth of 0.2 mm.

The results showed that the MCD coated CVD tool and the PCD tool
produced almost similar results, but the lowest cutting force was during
machining with an MCD cutter, where it was at feed rate (0.09 mm/rev)

25
and cutting speed (325 m/s). min) at a depth of cut (0.2 mm). They also
found that PCD instruments are five times more expensive than MCD
instruments. So the MCD tool would be a better alternative for aluminum
fabrication [10].

Deepak Mehra (2013). The researchers investigated the performance

of carbide tools to investigate tool life and wear behavior at various
manufacturing parameters. Tests were conducted with two types of cutting
processes (High Performance Cutting (HPC) and High Speed Cutting
(HSC)) in order to measure the performance of a cutting tool made of
Titanium Carbide (TiC) coated with two types of coatings (copper and
aluminium). The cutting was carried out using a lathe. Force analysis was
performed on a force scale. A number of experiments were carried out
under conditions of cutting speeds (250, 400, 600, 900 m/s), cutting depths
(0.5, 1, 1.5, 2, 2.5 mm) and feed rates (0.095, 0.18, 0.35 mm/rev).

The results showed that the lowest cutting force for the coated and
uncoated tools was (600 m/rpm), the cutting depth was (0.5 mm) and the
feed was (0.095 mm/rpm), and the lowest cutting force was for copper.
Coating with TiN was used [11].

Dr. Maan A. Tawfiq (2015). The researcher made attempts to

examine and simulate the effect of the coated layers on the components of
the cutting force in the orthogonal turning process using AISI 1010 steel.
A series of experimental and numerical tests were carried out with four
types of inputs including uncoated, (Titanium Nitride (TiN)) coated,
(Titanium Nitride (TiN)/ Titanium Carbonitride (TiCN)) and (Titanium
Nitride (TiN)/ Aluminium oxide (Al2O3)/ Titanium Carbonitride (TiCN)).
Rotation tests were conducted at five different cutting speeds (45, 65, 97,
145, and 206 m/min), while the feed rate and depth of cut were kept
constant at (0.2 mm/rev) and (1.2 mm), respectively.

26
 The results showed that minimal strength is achieved when TiN/TiCN
inlays are used compared to other inserts under all cutting conditions. The
TiN/TiCN cutting attachment is best at producing the lowest cutting force
in both tangential and feed forces. The reduction in transverse cutting force
was 7%, 4% and 2% when TiN/TiCN inserts were used compared to
uncoated, TiN/Al2O3/TiCN and TiN inserts, respectively. The maximum
relative difference between simulation and measurement values is less than
(17%) [12].

Vasu Mallesh; shivananda H Nayaka (2018); The researcher

studied the formation of EN47 steel samples on a self-centering lathe using
chemical vapor deposition to insert coated and uncoated tungsten carbide
tools. The researcher used EN-47 steel as the working material. The
experiment was carried out on a panther precision lathe with a spindle
speed ranging from 30rpm to 1250rpm.The experiment was conducted
based on the L9 Taguchi orthogonal array generated using the Minitab 17
software tool. Titanium Nitride (TiN)/ Aluminium oxide (Al2O3)/
Titanium Carbonitride (TiCN) coatings were used in the experiment

The results Using Taguchi L9 statistical technique output responses

are optimized, significance of inputs is determined and regression models
are developed for both coated and uncoated tool insert successfully during
machining of EN47 Steel. Coated tool insert (TICN/Al2O3/TIN) shows
slight difference 1.01 times better than uncoated insert tool in cutting force
[13].

Jaroslav Kovalčík et al (2022); The researcher focused on

developing a mathematical model for the cutting force applied to insert
coated and uncoated cutting tools and aims to enable a more accurate
calculation of cutting. Experiments were carried out on SP 430 SY 2 1100
CNC turning machines. The nominal speed of the machine was 141

27
revolutions per minute and the maximum speed was 3150 revolutions per
minute. minute. The researcher used the piezoelectric dynamometer 9257B
with the laboratory charge amplifier 5167A with integrated data
acquisition, and two commonly used coatings, Aluminum Titanium
Nitride (AlTiN) and Titanium Aluminum Chrome Nitride (TiAlCrN), were
used for work piece materials, and the researcher conducted a double t-test
with a confidence level of 0.05 to determine if there was a statistically
significant difference between the values of Calculated and experimental
cutting Force for uncoated and coated tools and for both AlTiN and
TiAlCrN coatings.

The result in the comparison of the experimental cutting force data for
the uncoated and coated inserts, there was a statistically significant
difference resulting from the paired t-test p-values (no coating-AlTiN: p-
value = 0.011; no coating-TiAlCrN: p-value = 0.024), which were below
the confidence level (α = 0.05). The percentage difference was found to be
up to 4%. In the comparison of the experimental cutting force data for the
two coated inserts, there was no statistically significant difference resulting
from the paired t-test p-value (p-value = 0.392), which was above the
confidence level (a = 0.05). This was despite the fact that the measured
properties of the coatings were slightly different. The percentage difference
was up to 1%; When the calculated cutting force data, which included the
coating correction factor, were compared with the experimental data of the
coated inserts, there was no states- tically significant difference resulting
from the paired t-test p-values (Model-AITIN: p- value = 0.234; Model-
TiAlCrN: p-value = 0.374), which were above the confidence level
(a=0.05). The percentage difference was found to be up to 0.6% [14].

Farhan K. Challab et al (2022); The researcher studied three

variables (cutting speed, feed rate, and depth of cut) for uncoated carbide

28
and multilayer coated carbide. The lathe was used with cutting conditions
of four cutting speeds (56,88,112,141) m/min and four feed rates (0.065,
0.08, 0.16, 0.228) mm/rev. A fixed depth of cut (1 mm) was used. The
experiments were carried out using AISI 1045 carbon steel work piece
material with a length (300 mm) and diameter (50 mm) divided into four
regions. This study investigated the performance of four coated and
uncoated PVD and CVD tools. Three types of coatings were used:
Titanium Nitride (TiN), Titanium Nitride (TiN)/Titanium Carbonitride
(TiCN), and Titanium Nitride (TiN)/ Aluminium oxide (Al2O3)/ Titanium
Carbonitride (TiCN).

The results show that the three-layer coating (TiN/A1203/TiCN) is

particularly effective in a range (32% to 39%) of uncoated inserts with
different cutting speeds and constant feed rates, with variable feed rates
and constant cutting speed and about less (34% to 40%) from uncoated
supplements [15]

29
 Experimental Investigation
3.1. Introduction
The modelling part of metal cutting simulation is very important step
to achieve accurate results. In this chapter, details of modelling tool, work
piece and cutting system are presented.
3.2. Tool Modelling
In analysis, cutting tool is assumed to be a rigid body as in figure (3.1).

Fig 3.1. the cutting tool

Geometric variables of the tool are given and Table (3.1)
Table 3.1. Geometric variables of the cutting tool
Rake Angle. B (𝑜 ) Clearance Angle. C (𝑜 ) Tip Radius. R (mm)
5 5 0.025
Uncoated tungsten carbide (WC) cutting tool material is selected. In Table
(3.2) the thermal and mechanical properties of (WC) and the coatings used
as well as the work piece are given.
Table 3.2. Thermal and mechanical properties

Properties WC TiN TiCN TiC Al2O3

Elastic Modulus, 426 324 294 340
650
E (GPA)
Poisson’s Ratio 0.25 0.25 0.23 0.19 0.22
Thermal Expansion
5 10.27 7.8 7.6 8.1
(1/ºC)* 10−6
Thermal Conductivity 29 35 37 32
50
(W/m-K)

30
3.3. Work piece Modelling
AISI 1045 steel has good machinability in a normalized or hot-rolled
condition. Based on the recommendations given by the machine
manufacturers, operations like tapping, milling, broaching, drilling,
turning and sawing can be carried out on AISI 1045 steel using suitable
feeds, tool type, and speeds.
Flow pressure modeling of work piece materials is very important to
achieve satisfactory results from metal cutting simulation as in figure (3.2).

Fig 3.2. section of the work piece

In the analysis, AISI 1045 was chosen as the work piece material. In the
Table (3.3) are some Properties of AISI 1045.
Table 3.3. Properties of AISI 1045.

Tensile strength 585 MPa

Yield strength 450 MPa
Modulus of elasticity 200 GPa
Shear modulus (typical for steel) 80 GPa
Poisson’s ratio 0.29
Elongation at break (in 50 mm) 12 %
Hardness, Brinell 163
Hardness, Rockwell B (converted from Brinell hardness) 84
Hardness, Vickers (converted from Brinell hardness) 170
Thermal conductivity 51.9 W/m K
Thermal expansion co-efficient (@0.000-100°C/32-212°F) 11.2 µm/m°C

31
3.4. Cutting Conditions
We used five different speeds and five different feeds with a constant
cutting depth. As in the Table 3.4.
Table 3.4. Cutting Conditions

cutting speed (m/min) Feed rate (mm/rev) Depth of cut (mm)

31.5 0.05 1
49.6 0.1 1
88.2 0.15 1
126 0.2 1
157.5 0.25 1

3.5. Finite Element Simulations Experiments

In this study, the Finite Element Method software DEFORM-2D,
which is based on Lagrangian formulation that employs implicit
integration method designed for large deformation simulations with
adaptive remeshing, is used to simulate the metal cutting process. The
Finite Element model is composed of a deformable work piece and a rigid
tool which discretized by bilinear four-node quadratic. The tool penetrates
through the work piece at a constant depth of cut and variable cutting
speeds and feed rates, and the finite element mesh is linked to the work
piece and follows its deformation. As mentioned in chapter four, our
software has the three main parts for building a model which are
preprocessing, simulation and post processing and will be discussed briefly
in the following sub-sections:
3.5.1. Preprocessing
The Finite Element model is composed of a deformable work piece
and a rigid tool. The tool penetrates through the work piece at a constant
cutting speed and feed rate. The first part of the modeling process contains
seven steps to build the model for our numerical work.

32
3.5.1.1. Process Setup
In this step the software will set the machining parameters such as
the surface speed of the spindle, feed rate and depth of cut.
3.5.1.2. Process Condition
Two steps are done; the first step is the input of environment
temperature, while the second step is the input of shear friction factor and
heat transfer coefficient.
3.5.1.3. Tool Setup
This is an important step in the modeling of machining operation. In
this step the tool geometry is designed (tool dimensions, rake angle and
clearance angle) and sketched using our software and also can be imported
from a data base file. Then the coating layer is selected, the cutting tool is
modeled to be coating as shown in Figure (3.3), in order to study in detail,
the behavior of the layer on the cutting forces. Then the mesh, boundary
condition of the tool and tool material was set.

Fig 3.3. Tool coated with one layer of TiN used in the simulation tests

3.5.1.4. Work piece Setup

This step is the same as the previous one; the work piece is designed
with user dimensions. Mesh generation is done automatically, boundary
condition and work piece material are as shown in Figure (3.4).

33
 Fig 3.4. Work piece setup

3.5.1.5. Setting Position

This code has the feature of setting the tool with the work piece
according to the feed rate input in the first step, Figure (3.5) shows the
positions of the tool against the work piece.

Fig 3.5. Setting position for the tool and work piece

3.5.1.6. Simulation Control

In this step the user must also set the number of simulation steps and
step increment to save the length of cut according to the design of the work
piece.

3.5.1.7. Database Generation

This is an important step that lets the user check the data which has
been input in the previous steps and a database file to start the simulation
being generated.

34
3.5.2. Simulation

The simulation will start automatically and lets the user check the
simulation through simulation graphic option.

3.5.3. Post-processing

The result will be shown to the user and will contain all the results
of the machining parameters such as (cutting forces on the tool and work
piece, stresses, strain, temperature, etc.). All these results will be shown as
a graph on both the tool and the work piece being machined as shown in
Figure (3.6)

Fig 3.6. General results of the FE model being suggested

35
 Results and Discussion
4.1. Introduction
In this chapter, the results of finite element simulations are
presented. Which relates to the cutting forces of different types of coatings
and different working conditions.

4.2. Effect of coatings and cutting conditions on cutting Force

Four different tungsten carbide tool coatings were tested, namely
titanium carbide (TiC), titanium nitride (TiN), titanium carbonate (TiCN)
and aluminum oxide (Al2O3). Also, our WC uncoated cutter has been
tested to cut AISI-1045 metal. Different speeds (31.5, 49.6, 88.2, 126,
157.5) (m/min), and different feeds (0.05, 0.1, 0.15, 0.2, 0.25) were used.
(mm/rev) as shown in Tables (1, 2, 3, 4 and 5).

In Table 1, we fixed the speed at (31.5 m/min) and chose different

feeds and several coatings for the cutting tool as well as the cutting tool
without coating. We note that the Al2O3 coating gives the lowest cutting
forces, where the tangential cutting force was (Ft = 115N) and the feed
force (Ff = 61N), at the feed rate (0.05mm/rev). While the highest values
of the cutting forces were when using the uncoated cutting tool where the
tangential cutting force was (Ft = 480N) and the feed force (Ff = 140N), at
a feed rate of (0.25mm/rev). (As in fig 4.1 (a and b)).

36
 Table 4.1. Effect of coatings on cutting force at cutting speed (V=31.5 m/min)

cutting Speed 31.5 m/min

0.05 0.1 0.15 0.2 0.25
Feed rate
mm/rev mm/rev mm/rev mm/rev mm/rev
Ft 145 233 317 411 480
Uncoated
Ff 74 95 117 132 140
Ft 140 226 311 405 470
TiN
Ff 69 90 113 128 135
Ft 130 224 303 395 462
TiCN
Ff 67 88 110 123 133
Ft 124 218 297 387 455
TiC
Ff 63 85 107 121 130
Ft 120 215 293 383 450
Al2O3
Ff 60 83 106 119 128

600 160
Al2O3 Al2O3
TiC TiC 140
TiCN 500 TiCN
TiN TiN 120
Uncoated 400 Uncoated
100

300 80
Ft

Ff
60
200
40
100
20

0 0
0.25 0.2 0.15
Feed 0.1 0.05 a 0.25 0.2 0.15
Feed 0.1 0.05 b
Fig 4.1.a. Cutting force _ b. Feed force. When cutting speed (V=31.5 m/min)

In Table 2, we fixed the speed at (49.6m/min) and chose different

feeds and several coatings for the cutting tool as well as the cutting tool
without coating. We note that the Al2O3 coating gives the lowest cutting
forces, where the tangential cutting force was (Ft = 120N) and the feed
force (Ff = 60N), at the feed rate (0.05mm/rev). While the highest values
of the cutting forces were when using the uncoated cutting tool where the

37
tangential cutting force was (Ft = 475N) and the feed force (Ff = 140N), at
a feed rate of (0.25mm/rev). (As in fig 4.2 (a and b)

Table 4.2. Effect of coatings on cutting force at cutting speed (V=49.6 m/min)

cutting Speed 49.6 m/min

0.05 0.1 0.15 0.2 0.25
Feed rate
mm/rev mm/rev mm/rev mm/rev mm/rev
Ft 137 226 311 398 475
Uncoated
Ff 76 100 118 134 140
Ft 132 220 305 392 471
TiN
Ff 71 94 114 130 137
Ft 129 215 302 387 466
TiCN
Ff 67 88 110 127 133
Ft 125 211 297 382 460
TiC
Ff 64 83 105 121 128
Ft 120 205 293 375 454
Al2O3
Ff 60 80 101 115 125

500 160
Al2O3 Al2O3
TiC 450 TiC 140
TiCN 400 TiCN
TiN TiN 120
Uncoated 350 Uncoated
300 100

250 80
Ft

Ff

200 60
150
40
100
50 20

0 0
0.25 0.2 0.15 Feed 0.1 0.05 a 0.25 0.2 0.15 Feed 0.1 0.05 b
Fig 4.2.a. Cutting force _ b. Feed force. When cutting speed (V=49.6 m/min)

In Table 3, we fixed the speed at (88.2 m/min) and chose different

feeds and several coatings for the cutting tool as well as the cutting tool
without coating. We note that the Al2O3 coating gives the lowest cutting
forces, where the tangential cutting force was (Ft = 116N) and the feed

38
force (Ff = 61N), at the feed rate (0.05mm/rev). While the highest values
of the cutting forces were when using the uncoated cutting tool where the
tangential cutting force was (Ft = 466N) and the feed force (Ff = 130N), at
a feed rate of (0.25mm/rev). (As in fig 4.3 (a and b)).

Table 4.3. Effect of coatings on cutting force at cutting speed (V=88.2m/min)

cutting Speed 88.2 m/min

0.05 0.1 0.15 0.2 0.25
Feed rate
mm/rev mm/rev mm/rev mm/rev mm/rev
Ft 132 221 305 385 466
Uncoated
Ff 77 96 111 123 130
Ft 127 215 302 381 459
TiN
Ff 74 93 107 119 125
Ft 123 212 297 376 455
TiCN
Ff 70 89 103 114 121
Ft 120 207 293 372 450
TiC
Ff 65 85 99 110 116
Ft 116 204 289 367 446
Al2O3
Ff 61 80 95 105 110

500 140
Al2O3 Al2O3
TiC 450 TiC 120
TiCN 400 TiCN
TiN TiN
350 100
Uncoated Uncoated
300
80
250
Ff
Ft

60
200
150 40
100
20
50
0 0
0.25 0.2 0.15
Feed 0.1 0.05 a 0.25 0.2 0.15
Feed 0.1 0.05 b
Fig 4.3.a. Cutting force _ b. Feed force. When cutting speed (V=88.2 m/min)

In Table 4, we fixed the speed at (126 m/min) and chose different

feeds and several coatings for the cutting tool as well as the cutting tool
without coating. We note that the Al2O3 coating gives the lowest cutting

39
forces, where the tangential cutting force was (Ft = 115N) and the feed
force (Ff = 64N), at the feed rate (0.05mm/rev). While the highest values
of the cutting forces were when using the uncoated cutting tool where the
tangential cutting force was (Ft = 466N) and the feed force (Ff = 127N), at
a feed rate of (0.25mm/rev). (As in fig 4.4 (a and b)).

Table 4.4. Effect of coatings on cutting force at cutting speed (V=126 m/min)

cutting Speed 126 m/min

0.05 0.1 0.15 0.2 0.25
Feed rate
mm/rev mm/rev mm/rev mm/rev mm/rev
Ft 131 219 306 384 466
Uncoated
Ff 80 99 113 121 127
Ft 127 213 300 379 461
TiN
Ff 76 95 108 115 120
Ft 124 209 295 375 455
TiCN
Ff 73 90 104 112 117
Ft 119 205 289 372 451
TiC
Ff 68 86 99 107 111
Ft 115 203 286 368 445
Al2O3
Ff 64 81 96 102 105

500 140
Al2O3 Al2O3
TiC 450 TiC 120
TiCN 400 TiCN
TiN TiN
350 100
Uncoated Uncoated
300
80
250
Ff
Ft

60
200
150 40
100
20
50
0 0
0.25 0.2 0.15
Feed 0.1 0.05 a 0.25 0.2 0.15
Feed 0.1 0.05 b
Fig 4.4.a. Cutting force _ b. Feed force. When cutting speed (V=126m/min)

In Table 5, we fixed the speed at (157.5 m/min) and chose different

feeds and several coatings for the cutting tool as well as the cutting tool

40
without coating. We note that the Al2O3 coating gives the lowest cutting
forces, where the tangential cutting force was (Ft = 115N) and the feed
force (Ff = 61N), at the feed rate (0.05mm/rev). While the highest values
of the cutting forces were when using the uncoated cutting tool where the
tangential cutting force was (Ft = 465N) and the feed force (Ff = 128N), at
a feed rate of (0.25mm/rev). (As in fig 4.5 (a and b)).

Table 4.5. Effect of coatings on cutting force at cutting speed (V=157.5 m/min)

cutting Speed 157.5 m/min

0.05 0.1 0.15 0.2 0.25
Feed rate
mm/rev mm/rev mm/rev mm/rev mm/rev
Ft 132 217 306 390 465
Uncoated
Ff 76 99 115 122 128
Ft 125 213 298 382 464
TiN
Ff 69 92 110 116 121
Ft 121 210 294 377 458
TiCN
Ff 66 88 105 109 114
Ft 117 205 289 372 452
TiC
Ff 64 85 99 103 108
Ft 115 203 286 369 447
Al2O3
Ff 61 82 95 100 105

500 140
Al2O3 Al2O3
TiC 450 TiC 120
TiCN 400 TiCN
TiN TiN
350 100
Uncoated Uncoated
300
80
250
Ff
Ft

60
200
150 40
100
20
50
0 0
0.25 0.2 0.15
Feed 0.1 0.05 a 0.25 0.2 0.15
Feed 0.1 0.05 b
Fig 4.5.a. Cutting force _ b. Feed force. When cutting speed (V=157.5m/min)

41
Conclusions and Recommendations for Future Work
5.1. Conclusions
Based on the experimental results presented, the following conclusions are
drawn on the effect of cutting speed and feed rate on the performance of
coated and uncoated carbide tools when turning AISI 1045 steel.

1. Coated carbide tools perform better than uncoated carbide tools as

far as cutting forces are concerned. For average magnitudes of forces
obtained with uncoated carbide tool were higher than those obtained
with coated carbide tools under experimental conditions.
2. Al2O3 coating is the best in producing the lowest cutting force in
each of the tangential cutting forces (Ft=115N) and the feeding force
(Ff=61N) at the cutting speed (157.5 m/min) and at the feed rate of
(0.05 mm/rev.).
3. The highest cutting force we get is when using the uncoated carbide
tool (Ft=132N, Ff=76N) at a cutting speed of (157.5 m/min) and a
feed rate of (0.05 mm/rev.).
4. The values of the cutting forces when using a carbide coated tool are
at their highest value when using TIN coating(Ft=125N, Ff=69N),
followed by TiCN coating(Ft=121N, Ff=66N), then TiC
coating(Ft=117N, Ff=64N) at a cutting speed of (157.5m /min) and
a feed rate of (0.05mm /rev.).
5.2. Recommendations for Future Work
The following research topics may be suggested for future work:
1. Study the effect of the number of coating layers on cutting forces..
2. Using other new cutting tool materials such as Poly Crystalline
Diamond (PCD), Cubic Boron Nitride (CBN), cermets and other
recent cutting tool materials.

42
 References

[1] J. Wang., The Effect of Multi-layer Surface Coatings of Carbide

Inserts on the Cutting Forces in Turning Operations, (2000).

[2] Ching Y. Choi., A Study of Oblique Cutting, Edinburgh, (1968).

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