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Wear Mechanisms in Cutting Tools for Machining Applications : Interfacial Phenomena, Characterization, and Relation to Performance

Lindvall, Rebecka LU (2024)
Abstract
Metal cutting technology plays an important role in the automotive and aeronautic sectors, both of which
are important for the Swedish economy. Both make use of traditional grey cast iron and difficult-to-
machine materials like titanium alloys and compacted graphite iron. The tools used to machine these
materials wear at varying rates depending on factors such as contact temperature, pressure, and the
relative motion of the workpiece material and the tool surface. Given that the machining process and the
production of tool and workpiece materials are energy intensive and generate waste, it is important to
improve the process sustainability. This can be achieved by improving machining conditions and... (More)
Metal cutting technology plays an important role in the automotive and aeronautic sectors, both of which
are important for the Swedish economy. Both make use of traditional grey cast iron and difficult-to-
machine materials like titanium alloys and compacted graphite iron. The tools used to machine these
materials wear at varying rates depending on factors such as contact temperature, pressure, and the
relative motion of the workpiece material and the tool surface. Given that the machining process and the
production of tool and workpiece materials are energy intensive and generate waste, it is important to
improve the process sustainability. This can be achieved by improving machining conditions and tooling
solutions, and by developing more wear-resistant tooling. Doing so requires knowledge of the wear
mechanisms that contribute to tool degradation.
The aim of this work is to expand knowledge of wear mechanisms in commercial tooling during
machining, to explore the phenomena occurring at the tool-chip/workpiece interface, and to explore the
driving forces that govern their intensity and relation to performance. Tools worn in turning and milling
applications and the related interfacial phenomena were explored after controlled variations in the cutting
environment. The methods used included freezing the cutting action, imitational experiments, and to a
lesser extent simulations or models of the wear processes. Samples generated by these experimental
methods were studied using scanning electron microscopy, X-ray energy-dispersive spectroscopy,
electron backscatter diffraction, ion channeling contrast, transmission electron microscopy, and X-ray
diffraction.
The major tool wear mechanisms include diffusional dissolution and formation of reaction products that
are either easily removed with the chip flow or that work as diffusion barriers. Additional chemical wear
through oxidation may occur in milling operations. Tool coatings are subject to mechanical wear and also
to some degree to diffusional dissolution. The combination of several titanium alloys including
commercially pure titanium, near-α Ti-6Al-2Sn-4Zr-2Mo, α+β Ti-6Al-4V, α+β Ti-6Al-2Sn-4Zr-6Mo, and
near-β Ti-5Al-5V-5Mo-3Cr, compacted graphite iron, and grey cast iron with tooling including
polycrystalline diamond, polycrystalline cubic boron nitride, uncoated cemented carbide grades and
coated versions including physical vapor deposition applied Ti 0.45Al 0.55N with or without NbN overlayer
and chemical vapor deposition applied Ti(C,N)-Al 2O3 makes for many variants of reaction products,
intensity of wear mechanisms, performance, and ways to decrease the wear rate. (Less)
Please use this url to cite or link to this publication:
author
supervisor
opponent
  • Assoc. Prof. Bissacco, Giuliano, DTU, Denmark.
organization
publishing date
type
Thesis
publication status
published
subject
pages
270 pages
publisher
Department of Mechanical Engineering and Sciences, Faculty of Engineering LTH, Lund University.
defense location
Lecture Hall M:D, building M, Ole Römers väg 1, Faculty of Engineering LTH, Lund University, Lund. The dissertation will be live streamed, but part of the premises is to be excluded from the live stream. Zoom: https://lu-se.zoom.us/j/69026004210?pwd=ZFMzSzFET3JIZmpBUnBjODZLOGx4UT09
defense date
2024-05-24 10:00:00
ISBN
978-91-8039-963-0
978-91-8039-962-3
language
English
LU publication?
yes
id
24ef45e1-655b-4fda-b4ef-d55480ffc76b
date added to LUP
2024-04-09 13:52:19
date last changed
2024-04-26 09:33:32
@phdthesis{24ef45e1-655b-4fda-b4ef-d55480ffc76b,
  abstract     = {{Metal cutting technology plays an important role in the automotive and aeronautic sectors, both of which<br/>are important for the Swedish economy. Both make use of traditional grey cast iron and difficult-to-<br/>machine materials like titanium alloys and compacted graphite iron. The tools used to machine these<br/>materials wear at varying rates depending on factors such as contact temperature, pressure, and the<br/>relative motion of the workpiece material and the tool surface. Given that the machining process and the<br/>production of tool and workpiece materials are energy intensive and generate waste, it is important to<br/>improve the process sustainability. This can be achieved by improving machining conditions and tooling<br/>solutions, and by developing more wear-resistant tooling. Doing so requires knowledge of the wear<br/>mechanisms that contribute to tool degradation.<br/>The aim of this work is to expand knowledge of wear mechanisms in commercial tooling during<br/>machining, to explore the phenomena occurring at the tool-chip/workpiece interface, and to explore the<br/>driving forces that govern their intensity and relation to performance. Tools worn in turning and milling<br/>applications and the related interfacial phenomena were explored after controlled variations in the cutting<br/>environment. The methods used included freezing the cutting action, imitational experiments, and to a<br/>lesser extent simulations or models of the wear processes. Samples generated by these experimental<br/>methods were studied using scanning electron microscopy, X-ray energy-dispersive spectroscopy,<br/>electron backscatter diffraction, ion channeling contrast, transmission electron microscopy, and X-ray<br/>diffraction.<br/>The major tool wear mechanisms include diffusional dissolution and formation of reaction products that<br/>are either easily removed with the chip flow or that work as diffusion barriers. Additional chemical wear<br/>through oxidation may occur in milling operations. Tool coatings are subject to mechanical wear and also<br/>to some degree to diffusional dissolution. The combination of several titanium alloys including<br/>commercially pure titanium, near-α Ti-6Al-2Sn-4Zr-2Mo, α+β Ti-6Al-4V, α+β Ti-6Al-2Sn-4Zr-6Mo, and<br/>near-β Ti-5Al-5V-5Mo-3Cr, compacted graphite iron, and grey cast iron with tooling including<br/>polycrystalline diamond, polycrystalline cubic boron nitride, uncoated cemented carbide grades and<br/>coated versions including physical vapor deposition applied Ti 0.45Al 0.55N with or without NbN overlayer<br/>and chemical vapor deposition applied Ti(C,N)-Al 2O3 makes for many variants of reaction products,<br/>intensity of wear mechanisms, performance, and ways to decrease the wear rate.}},
  author       = {{Lindvall, Rebecka}},
  isbn         = {{978-91-8039-963-0}},
  language     = {{eng}},
  month        = {{04}},
  publisher    = {{Department of Mechanical Engineering and Sciences, Faculty of Engineering LTH, Lund University.}},
  school       = {{Lund University}},
  title        = {{Wear Mechanisms in Cutting Tools for Machining Applications : Interfacial Phenomena, Characterization, and Relation to Performance}},
  url          = {{https://lup.lub.lu.se/search/files/179374862/Avhandling_Rebecka_Lindvall_utan_papers_Lucris.pdf}},
  year         = {{2024}},
}