COMPARISON BETWEEN PVD AND CVD+PVD COATED INSERTS FOR CUTTING FORCES AND TOOL WEAR DURING TURNING OF RAMAX-2

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1 COMPARISON BETWEEN PVD AND CVD+PVD COATED INSERTS FOR CUTTING FORCES AND TOOL WEAR DURING TURNING OF RAMAX-2 M.A. Zeb 1, S.C. Veldhuis 2, M.A. Irfan 1, HamidUllah 1 1 NWFP University of Engineering & Technology, Peshawar, Pakistan 2 McMaster University, Hamilton, ON Canada ABSTRACT A comparison is made between PVD coated and CVD+PVD coated inserts during machining of Ramax-2 (a stainless steel mould material). The cutting forces are measured using Kistler lathe tool dynamometer, first using PVD coated inserts and then CVD+PVD coated inserts. The flank wear of these inserts is observed by machining Ramax-2 at the optimum parameters. The surface finish is also measured with portable surface roughness meter. The results shows that Ramax-2 can be economically cut if CVD+PVD coated inserts are used. The tool life with CVD+PVD coated inserts is found higher as compared to PVD coated inserts, although the surface roughness and cutting forces are almost the same for both kinds of inserts. Keywords: Turning; CVD; PVD; Stainless steel; Cutting forces; Roughness; Wear 1. INTRODUCTION The mold making industry is growing rapidly due to the enhanced demand placed by plastic products [1,2]. There is an increasing demand by the industry to find advanced materials for mold making which offer a longer life for the mold coupled with good machinability of the mold [3, 4]. Enhancing the life of tools to machine such mold materials are an area of active research concern [5]. Ramax-2 is martensitic steel with excellent machinability and good corrosion resistant properties. It properties are comparable to AISI 420 F stainless steel. It can be machined at increased cutting speeds. It is mostly used for holders/bolsters for plastic moulds. In this paper Ramax-2 is machined with two different kinds of inserts, Physical Vapor Deposition (PVD) and Physical cum Chemical Vapor Deposition (PVD+CVD) at various cutting conditions. The cutting forces, surface finish, and tool wear for each case, are measured and hence recommendations are made for the most efficient way to machine Ramax-2. Researchers [6, 7, 8] had shown PVD coated cemented carbide tools performing better than CVD coated tools. TiN was used in the first generation PVD coated carbide 1

2 tools, whereas TiCN and TiAlN were used in the second generation and third generation PVD coated tools.[9]. The process of PVD is carried out at low temperatures, which leaves the toughness and strength of the substrate unaffected. Moreover the tool life of PVD coated tools is less than CVD coated tools primarily due to poor adhesion of the coating in PVD. Thus PVD coated tools find limited application in the cemented carbide tool industry as compared to the CVD coated tools [10]. Commercial Alumina coated tools are produced at relatively high temperatures around 1000 o C. This leads to thermal cracking in the coating due to a difference in coefficient of thermal expansion between the tools and the coating [11]. Therefore, for this study the commercially available CVD Al 2 O 3 coated insert was further coated with 3µm AlTiN layer by PVD cathodic arc deposition technique to give increased toughness and tool life. The Ramax-2 workpiece was machined first with commercially available PVD coated carbide insert and then with the tailor made insert as stated above. 2. EXPERIMENTAL PROCEDURE Ramax-2 specimens 105 mm in diameter and 310 mm in length are used for the machining tests. Single point turning without coolant is carried out on Boehringer VDF180 Cm CNC turning centre. Kistler 9121 piezoelectric dynamometer is used to measure forces. The dynamometer is interfaced with a compute through Labview software. The surface roughness of the machined surface is done on a Mitutoyo Surface SJ-201 instrument. The tool wear is inspected under Mitutoyo TM microscope and the tool wear photographs are taken with Nikon SMZ1000 microscope incorporating a digital camera. Table 1 gives the chemical composition of the work-piece material [12]. Table 2 shows the mechanical and physical properties [12]. The samples are taken from a round bar of 28 mm diameter. Table 1. Chemical composition of the work-piece material (% wt.) Material C Si Mn Cr S Fe Ramax Table 2. The mechanical and physical properties of the workpiece material Testing Tensile Modulus of Yield strength Hardness temperature strength elasticity ( o (MPa) (HB) C) (MPa) (GPa)

3 Two different kinds of cemented carbide inserts are used. The first insert is commercial PVD multi-layer (TiCN/TiN) coated cemented carbide insert. These are produced by Sandvik with the specification VNMG MF, VNMG 331-MF. These inserts are generally used for finishing of stainless steel and have GC1025 Sandvik grade. Second kind of insert is commercial CVD with a total thickness of 10 microns including a thick layer of alumina on top of a medium sized layer of Ti(C,N). The Sandvik specification for these inserts i VNMG MF, VNMG 331-MF. These are recommended for cutting stainless steel at relatively high cutting speed and have GC4025 Sandvik grade. These inserts are further coated with 3µm AlTiN layer by PVD cathodic arc deposition technique. With this kind of composite CVD+PVD coatings harder materials can be machined at elevated speeds because the thermal cracking of CVD Al 2 O 3 coated inserts is offset by the PVD coating at lower temperature. A negative rake angle of -4 is used for both kinds of inserts. The nose radius of both of these inserts is 0.4 mm. First test is carried out at cutting speed of 100 m/min and with depth of cut of 1 mm. The feed rate is varied from 0.1 mm/rev to 0.5 mm/rev, in steps of 0.1 mm/rev. Second test is carried out at a cutting speed of 100 m/min and at a feed of 0.2 mm/rev. The depth of cut is varied from 0.2 mm to 1 mm, in steps of 0.2 mm. Third test is carried out at a depth of cut of 1 mm with feed of 0.2 mm/rev. The cutting speed is varied from 50 m/min to 250 m/min, in steps of 50 m/min. The length of cut is 20 mm and the cutting forces are recorded for 1 second of cut after the tool is in stable cutting process. The forces for the first 100 msec are averaged to draw the graphs in each case. 3. RESULTS AND DISCUSSION 3.1 Cutting Forces The variation of three cutting forces using PVD insert and CVD+PVD inserts. All these forces increase with increasing the feed rate is shown in Figure 1. It is seen that PVD coated inserts exhibit lower cutting forces than those for CVD+PVD coated inserts. The slope of these forces is smaller at lower feeds as the surface roughness is lower. As the feed rate increases beyond 0.3 mm/rev the forces increase with a larger slope because surface roughness increases. The increased forces endured by the tool tip lead to a rapid tool wear. 3

4 Figure 2 shows the cutting forces for the two inserts used. All these forces are proportional to the depth of cut. The effect of the depth of cut is same for each cutting force. At 0.4 mm depth of cut the thrust force (feed force) becomes high (158 N) involving a rapid flank wear and chipping. Also, the forces are higher in case of CVD+PVD coated inserts. Thus, it can be concluded that although the cutting forces are higher for CVD+PVD coated inserts as compared to PVD coated, keeping all the parameters same, the only advantage of CVD+PVD coated inserts is that these can take up higher temperature and pressure loads and are more suitable in high speed machining regime. 4

5 Figure 3 shows that all the three cutting forces i.e., main cutting force, the feed force, and the radial force are inversely proportional to cutting speeds. The increase in cutting speeds leads to thermal softening of the work-piece which in turn lowers the cutting force. It can be seen from force lines of Figure 3 that between 100 m/min and 150 m/min, the thermal softening effect is dominating but after 150 m/min, the rate of decrease of these forces is lesser, which indicates a competing phenomenon between work-hardening and thermal softening. Again, the forces are higher in case of CVD+PVD coated inserts. 5

6 3.2 Surface roughness Figure 4 shows the increase in the surface roughness (R a ) with the increase in the feed rate for both kinds of inserts. In comparison to Figure 5 and Figure 6 which show the surface roughness variations vs. depth of cut and vs. speed respectively, the surface deterioration rate is much rapid and higher when the feed rate is increased as shown in Figure 4. It reaches to 22 microns at a feed of 0.5 mm/rev. For feed rates is below 0.4 mm/rev the surface roughness is about 7 microns, because the tool nose radius is 0.4 mm therefore below 0.4 mm/rev feed rate the surface finish is good. 6

7 It can be seen from Figure 5 that the surface finish remains below 4 microns with the increase in depth of cut. Further there is no significant change in the surface finish for both kinds of inserts. It is an established fact that in machining the surface deterioration and tool life is directly affected by feed rate then by cutting speed and then by depth of 7

8 cut. Hence, good surface finish with increasing depth of cut is observed. Figure 6 shows that increasing the cutting speed leads to improved surface finsih. The tool endures lesser forces with the increase in the cutting speed. Consequently, the tool wear is less leading to improved surface finish. 3.3 Tool wear Friction between the newly machined work-piece and flank is the prime reason for tool wear. The amount of wear is usually quantified be the width of the wear land which can easily be measured on a microscope. Figure 7 shows the wear curve divided into three distinct regions. The first region is depicted by AB. Here the sharp cutting edge is broken down and a wear land is formed. The second region is BC where wear takes place at a uniform rate. The third region is CD where wear occurs at an increasing rate. The ISO criteria for flank wear of carbide tools is VB = 0.3 mm, for conditions where flank is regularly worn in zone B. The same type of general tool wear curve is obtained for the inserts used in this experiment and the VB = 0.3 mm criterion is adopted to predict the maximum length cut by each insert. On comparison between Figure 7 and Figure 8, the advantage of having a CVD+PVD composite coating can be appreciated. The length of cut for CVD+PVD 8

9 composite coated insert is about two and a half times greater then the length cut by the PVD coated insert for identical values of depth of cut, feed rate, and cutting speed. 9

10 4. CONCLUSIONS PVD coating makes the cutting tool tougher and the possibility of thermal crack development, after cooling, is less, as compared to CVD coated inserts. However, the tool is less wear resistant in case of PVD coatings as proved by the experimental results. The tool life of composite CVD+PVD coated inserts is two and a half times greater than the PVD coated inserts. Appreciable advantage is not seen with CVD+PVD coated inserts as far as the cutting forces are concerned. For Ramax-2, the composite CVD+PVD coated inserts will give higher production rates than commercially available PVD coated inserts, and the production process will be economical, as lesser inserts will be utilized. REFERENCES 1. Neto, V.F., Oliveira, M.S.A., Ali, N., and Gra cio, J., Time-modulated chemical vapor deposition diamond on mould making 2738 steel. Vacuum, Vol. 82, pp Sharman, A.R.C., Amarasinghe, and Ridgway A., K., Tool life and surface integrity aspects when drilling and hole making in Inconel 718. Journal of materials processing Technology, Vol. 200, pp

11 3. Jianxin, D., Jianhua, L., Jinlong, Z., and Wenlong, S., Wear mechanisms of PVD ZrN coated tools in machining. International Journal of Refractory Metals & Hard Materials, Vol. 26, pp Nalbanta, M., Go Kayab, H., Toktas-a, I., and Sura, G., The experimental investigation of the effects of uncoated, PVD- and CVD-coated cemented carbide inserts and cutting parameters on surface roughness in CNC turning and its prediction using artificial neural networks. Robotics and Computer-Integrated Manufacturing, pp MinLee, S., Chow, H., Huang, F.Y., and Yan, B.H., Friction drilling of austenitic stainless steel by uncoated and PVD AlCrN-and TiAlN- coated tungsten carbide tools. International Journal of Machine Tools & Manufacture, Vol. 49, pp Tsukamoto, T., Sasaki, K., Shibuki, K., Momma, H., and Takasu, S., Advances in hard metal production. Conference Proceedings, Luzern, Switzerland, pp Quinto, D.T., Santhanam, A.T., and Jindal, P.C., Mechanical Properties, Structure and Performance of Chemically Vapour deposited and Physically Vapour-deposited Coated Carbide Tools. J. of Material Science and Engineering. A , pp Santhanam, A.T., Quinto, D.T., and Grab, G., Comparison of the steelmilling performance of carbide inserts with MTCVD and PVD TiCN coatings Int. J. of Refractory Metals and Hard Materials, Vol. 14, pp Jindal, P.C., Santhanam, A.T., Schleinkofer, U., and Shuster, A.F., Performance of PVD TiN, TiCN, and TiAlN coated cemented carbide tools in turning. Int. J. of Refractory Metals and Hard Materials, Vol. 17, pp Konyashin, I. Yu., PVD/CVD technology for coating cemented carbides. Int. J. of Surface & Coatings Technology, Vol. 71, pp Astran, M., Selinder, T.I., Fietzke, F., and Klostermann, H., PVD-Al 2 O 3 - coated cemented carbide cutting tools. Int. J. of Surface & Coatings Technology Vol , pp Bohler Uddeholm Australia, RAMAX 2, Pre-hardened stainless holder steel, accessed on November 17,

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