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Cutting is an important process in the manufacturing industry. It is necessary to use good quality cutting tools in order to maintain the quality of a product. The coating on a cutting tool has a great impact in terms of the mechanical and tribological properties as well as the end results of the product. A cutting tool can made of various types of...
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The CrZrN/CrZrSiN multilayer coatings at a bilayer period range decreasing from 1.35 μm to 0.45 μm were synthesized on a Si (100) wafer and WC-6 wt.% Co substrate using a closed-field unbalanced magnetron sputter, and the thickness effects on the mechanical properties and thermal stability were investigated. The CrZrN/CrZrSiN multilayer coatings sh...
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... It can be synthesized much more affordably when ductile metallic binders are used, and it can withstand hostile environments [2]. It is extensively used in cutting tools and high-wear components due to its superior hardness (20.4 GPa), high melting point (>3000 K), great thermal stability, and anti-oxidation properties [3,4]. Due to their excellent wear resistance and robust thermal stability, cemented carbides containing tungsten carbide (WC) with metal binders such as cobalt (Co) and nickel (Ni) find applications as inner coatings in the emerging field of nuclear energy generation and reactor technology, that is molten salt reactors [5]. ...
Tungsten carbide (WC) is an important material to study for various applications in extreme environments due to its radiation-resistant properties and high mechanical strength. Due to its excellent properties such as high hardness, strength, and wear resistance, it is also being considered lately as a plasma facing component in nuclear fusion reactors. To study the response of this material in extreme radiation environments, WC films prepared using RF sputtering technique were irradiated with 100 MeV Ag 8+ ions in the present work. The irradiation was carried out at three different fluences: 3 × 10 12 , 1 × 10 13, and 3 × 10 13 ions/cm 2. Rutherford Backscattering Spectrometry (RBS) was performed to determine the stoichiometry and thickness of the pristine film. To study the irradiation-induced modifications, glancing angle X-ray diffraction (GAXRD), field emission scanning electron microscopy (FE-SEM), High Resolution Transmission Electron Microscopy (HRTEM), and Raman spectros-copy were performed on the pristine and irradiated samples. GAXRD of the pristine and irradiated samples revealed grain size reduction accompanied with reduced crystallinity with increasing ion fluence which was further manifested in HRTEM measurements and Raman spectroscopy measurements. Change in surface morphology due to the ion irradiation was observed in FE-SEM. These modifications have been explained using thermal-spike and TRIM simulations which showed that although the swift heavy ions irradiation did not result in track formation in the WC films, it caused radiation damage which may be attributed to the synergistic effect of electronic and nuclear energy loss mechanisms. These results might be crucial for a fundamental understanding of the radiation resistance of WC thin films and its application in different radiation environments.
... Over nearly five decades, the industry has relied on chemical vapor deposition (CVD) [20,21], physical vapor deposition (PVD) [22,23], or hybrid methods [24] for coating 85% of cemented carbide tools. Evolving coating materials through CVD and PVD technology [25,26], including rapid adoption of nanostructured PVD coatings, aligns with the industry's pursuit of enhanced tools. The historical success of coated cutting tools highlights their significance, and integrating high-performance coatings on improved cutting materials and innovative tool designs holds promise for meeting future tooling needs, fostering sustainability in machining. ...
... According to the recent trend in industries, more than 80 % is still a top-down process, with machining dominating as several processes, such as turning, milling, drilling, etc., are used to achieve the desired final output. According to a research survey conducted by Atiqah [2] and Rizzo [1], the trends in cutting tool materials are shown in Fig. 1. Fig. 1 shows that in 2013, the percentage usage of the most common cutting tool materials was cemented carbides (53 %) and highspeed steels (HSS) (20 %), and the rest were ceramics, cBN/PcBN, diamond and cermets. ...
This review paper critically emphasizes the possibilities and recent developments for producing high-performance conventional cutting tools that are in demand in the traditional machining industry. These cutting tools are considered for use in traditional machining of materials that provide a high strength-to-weight ratio for various applications with high precision. This review focuses on the machinability of turning, milling, drilling, and other special tools manufactured using various additive manufacturing methods. The materials and methods used are also studied, enabling us to understand the vast requirements of tool materials and the additive manufacturing methods available for production. The critical suggestions discussed would establish a platform for the selection of printing methods and printing strategies to develop cutting tools with complex internal geometries.
... ese improved models simplify the resolving of challenges related to the modernday machining technology, which focuses at continuous life extension of cutting tools while maintaining high-speed cutting to the maximum possible. Obviously, mitigating these challenges in turn makes productivity and improvement of quality possible along with its bene ts of economizing energy and material consumption [2][3][4][5][6][7][8][9][10][11][12][13]. ...
... In this environment of high thermomechanical stresses, the tool material structure and properties should provide maximum resistance to the destruction of tool contact regions [5][6][7]. If the loads around the cutting area of the tool do not surpass the limits of strength characteristics of the tool material, that will have an impact of change in the structure of the material in the speci c area due to work hardening [8][9][10]. ...
... Noting that the metal-working industries had taken major steps in identifying various kinds of cutting ceramic (CC) which do not comprise deficient elements, constitute elevated hardness ranging between HRA 91 and 94 and thermal resistance up to 1450°C, are wear resistive, and are manufactured through comparatively easy and cost-efficient technology [7,9,73]; the research by [73] insists on the need for further improvement to CC for many reasons. e major reasons include the fact that cutting ceramics (CC) are usually known for their low viscosity and resistance to bending, embrittlement, and reduced thermal resistance. ...
One of the major causes of railway accidents is reported to be unfavourable rail joint conditions. These
have resulted in a number of human and financial losses for passengers, rail transport companies and
other stakeholders of the railway industry. In railway transportation, the rail end joint is the weakest
component mainly due to the abrupt discontinuity of the rail along with the changes of the structure,
geometries and other factors such as mechanical properties. Recent studies show that the most wide-
spread defects occur at the bolt-hole and in the upper fillet area of the rail end. This paper specifically
investigated the effects of vertical wheel loading on rail end joint using finite element method, ANSYS
Workbench Version 19.2. Here the vertical displacement, principal and shear stress at bolt holes are stud-
ied in depth. Results indicated that for centre supported joint, the stress nearby the bolt hole is substan-
tially below the ultimate strength (20%), similarly, for the near to support scenario, the stresses around
the bolt hole are below the ultimate strength (25%). However, suspended joint experienced large normal
displacement along with high stresses around the bolt hole. Hence, it is concluded that for a better per-
formance and more reliable operations of railway tracks, fully center-supported joints are recommended.
... For this purpose, the surface roughness generated by CBN7050 and CC620 ceramic is better compared to the other two cutting materials tested (CC1690 and CC6050). The reason for this difference is attributed to the mechanical characteristics and chemical composition of each cutting material, similar explanations are reported by (Badaluddin et al. 2018, Rumiantseva et al. 2020 Fig. 7 (a)-(b) shows the evolution of Fx, Fy and Fz as a function of (Vc) for the four cutting inserts tested. It can be underlined that (Fy) is preponderant, followed by (Fz) and lastly (Fx) for the two cutting speeds tested. ...
The purpose of this research is to assess the performance of CBN and ceramic tools during the dry turning of gray cast iron EN GJL-350. During the turning operation, the variable machining parameters are cutting speed, feed rate, depth of cut and type of the cutting material. This contribution consists of two sections, the first one deals with the performance evaluation of four materials in terms of evolution of flank wear, surface roughness (2D and 3D) and cutting forces. The focus of the second section is on statistical analysis, followed by modeling and optimization. The experiments are conducted according to the Taguchi design L32 and based on ANOVA approach to quantify the impact of input factors on the output parameters, namely, the surface roughness (Ra), the cutting force (Fz), the cutting power (Pc), specific cutting energy (Ecs). The RSM method was used to create prediction models of several technical factors (Ra, Fz, Pc, Ecs and MRR). Subsequently, the desirability function approach was used to achieve a multi-objective optimization that encompasses the output parameters simultaneously. The aim is to obtain optimal cutting regimes, following several cases of optimization often encountered in industry. The results found show that the CBN tool is the most efficient cutting material compared to the three ceramics. The optimal combination for the first case where the importance is the same for the different outputs is Vc=660 m/min, f=0.116 mm/rev, ap=0.232 mm and the material CBN. The optimization results have been verified by carrying out confirmation tests.
... Cutting tools are made of different types of materials such as carbon tool steel, high-speed steel, cemented carbide, boron nitride, and diamond tools [2]. All these materials have different mechanical and tribological properties, but particularly for steel cutting applications, cemented tungsten carbide is a commonly used material in the manufacturing industry. ...
Cutting is an important process in the manufacturing industry and cutting tool is an important element in machining. It is essential to use good quality cutting tools in arrange to maintain the quality of a product. To retain the performance of cutting tool, various techniques have been utilized like cutting fluid, cutting under MQL, coating, multilayer coating, cryoprocessing, different types of surface texturing, different types of solid lubricants, etc. All these processes have a great impact to enhance the mechanical, thermal, and tribological properties in case of conventional machining process. Nowadays composite engineered materials are very successful in metal cutting industry due to its wear-related application and excellent mechanical and thermal properties. A very few research has been carried out on graphene mixed composite tool material, which has very high demand in manufacturing industries, due to its application as a cutting tool material for machining of Al, copper, or high strength carbon steel. In the end, challenges in the processing of tungsten carbide graphene mixed self-lubricated tool have been identified from the literature. In parallel, the latest improvements to enhance the properties of tungsten carbide-cobalt cutting tool with graphene mixed are reviewed.
... It can be synthesized much more affordably when ductile metallic binders are used, and it can withstand hostile environments [2]. It is extensively used in cutting tools and high-wear components due to its superior hardness (20.4 GPa), high melting point (>3000 K), great thermal stability, and anti-oxidation properties [3,4]. Due to their excellent wear resistance and robust thermal stability, cemented carbides containing tungsten carbide (WC) with metal binders such as cobalt (Co) and nickel (Ni) find applications as inner coatings in the emerging field of nuclear energy generation and reactor technology, that is molten salt reactors [5]. ...
... An adhesion promoting metallic interlayer is often deposited in between the ceramic coating and the substrate, forming a coating/interlayer/substrate sandwich structure. For example, such thin film sandwich structures are now routinely employed in tool coatings [17]. The laser spallation test has been used to measure the tensile strengths of interfaces between thin films/coatings and substrates with and without adhesion-promoting interlayers, and can generate quantitative results on films with sub-micron thicknesses. ...
A combined experimentation - molecular dynamics simulation study was conducted to understand tensile failure of TiN/Cu/TiN interfacial regions. Tensile loading was conducted on micro-pillar specimens fabricated from TiN/Cu/TiN thin film sandwich structures. The Cu layer and the TiN layer underneath were grown epitaxially on MgO(001) substrates, with Cu[110]//TiN[001] in the growth direction and Cu<111>//TiN<100> and Cu<112>//TiN<100> within the growth plane. The Cu layer contains numerous nanotwins with the {111} twin plane parallel to the growth direction, with 2–10 nm wide twin bands rotated in-plane by 90° in different yet symmetry-equivalent epitaxial domains. Tensile loading in-situ a scanning electron microscope measured tensile fracture stress ∼1.5 GPa and revealed a surprising failure mode transition. At a larger Cu layer thickness, ductile tensile fracture occurred within the Cu layer. At smaller Cu layer thicknesses, apparently brittle fracture occurred close to or at the Cu/TiN interface. The accompanying molecular dynamics simulations illustrate a significant dependence of the failure mode on the aspect ratio of Cu pillars under tensile loading. With pillars of small height-to-diameter ratios, tensile loading leads to a significant hydrostatic tension within, as well as significant plasticity throughout the Cu pillar, in particular near the top and bottom Cu/TiN interfaces. The high degree of dislocation activities close to or at the interface, combined with dislocation pile-up, serves to create nanovoids. The high hydrostatic tension furnishes a driving force for growth of such nanovoids, leading to rapid tensile fracture. The simulation results offer an analogy to experimental observations and mechanistic understanding of tensile failure mechanisms for ceramic/metal/ceramic interfacial regions.
... The thin layer(s) covering the surface of cutting tools, hereafter referred to as coatings, can be defined by many different properties. These properties, such as hardness, thickness, tribological behavior, surface roughness of the machined surface, chemical and thermal stability and oxidation resistance [Mrkvica 2015, Badaluddin 2018, only offer an approximate indication of the behavior of the coating in a specific application. All of the properties of the coating are often hidden under the mask of trade secret. ...
Thin hard layers deposited on cutting tools known as ‘coatings’ serve as a protective barrier against abrasion and adhesion wear, while also protecting against thermal and chemical processes that deteriorate the cutting performance of the tool. Coating properties including non-zero thickness, surface roughness, and chemical composition affect the cutting process significantly when compared to uncoated tools. The mechanical properties of coatings can be compared using specific, standardized measurement methods that provide indirect information about the behavior of the coating in a given application of the machining. In practice, it is necessary to evaluate the cutting ability by experimental testing of a given combination of cutting tool, workpiece, cutting conditions and cutting environment. This article discusses various experimental procedures that help to recognize the suitability of a coating for a particular application. These procedures can be applied alone, or in combination, as required by the cutting process. Each of these procedures have associated advantages and disadvantages, as described in this paper.
... ese improved models simplify the resolving of challenges related to the modernday machining technology, which focuses at continuous life extension of cutting tools while maintaining high-speed cutting to the maximum possible. Obviously, mitigating these challenges in turn makes productivity and improvement of quality possible along with its bene ts of economizing energy and material consumption [2][3][4][5][6][7][8][9][10][11][12][13]. ...
... In this environment of high thermomechanical stresses, the tool material structure and properties should provide maximum resistance to the destruction of tool contact regions [5][6][7]. If the loads around the cutting area of the tool do not surpass the limits of strength characteristics of the tool material, that will have an impact of change in the structure of the material in the speci c area due to work hardening [8][9][10]. ...
... Noting that the metal-working industries had taken major steps in identifying various kinds of cutting ceramic (CC) which do not comprise deficient elements, constitute elevated hardness ranging between HRA 91 and 94 and thermal resistance up to 1450°C, are wear resistive, and are manufactured through comparatively easy and cost-efficient technology [7,9,73]; the research by [73] insists on the need for further improvement to CC for many reasons. e major reasons include the fact that cutting ceramics (CC) are usually known for their low viscosity and resistance to bending, embrittlement, and reduced thermal resistance. ...
The challenge of enhancing cutting tool life has been dealt with by many research studies. However, this challenge seems endless with growing technological advancement which brings about incremental improvement in tool life. The objective of this review paper is focused at assessing filtered cathodic vacuum arc deposition techniques applied on cutting tools and their effect on tool efficiency. The paper particularly picks filtered cathodic vacuum arc deposition (FCVAD) among other well-identified methods of coating like the Chemical Vapor Deposition (CVD) and Physical Vapor Deposition (PVD). Filtered Cathodic Vacuum Arc Deposition is the state of art in the coating technology finding wide application in the electronics industry and medical industry in addition to the machining industry, which is the concern of this review paper. This review is made in order to summarize and present the various techniques of FCVAD coatings and their applications, as investigated by various researches in the area.
