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COATED INSERTS
Jorge A. Olortegui-Yume and Patrick Y. Kwon
Department of Mechanical Engineering, Michigan State University, East Lansing, MI
ABSTRACT
This paper deals with understanding the
evolution of tool wear of multilayer coated
inserts using Confocal Laser Scanning
Microscopy (CLSM). Steady-state turning
experiments were carried out on 1045 steel bars
with commercially available multi-layer coated
inserts consisting of TiN /Al2O3 /TiCN deposited
on a C6 carbide substrate provided by
Kennametal, Inc.. Topographical images of the
crater wear as well as orthogonal sections of the
flank and crater wears as functions of machining
time are obtained. A humped island of TiN
coating material next to a growing crater of Al2O3
and steel traces were found. The maximum
crater depth value and location respect to the
edges of the insert are gathered for all
machining times. The maximum crater depth
location was observed to move across the rake
face as machining time increased. These
unexpected features of crater wear are
suspected to have their origin in the competition
of the abrasive and dissolution mechanisms,
and the difference in wear-resistant properties
between the TiN and Al2O3 coatings. Validations
of the confocal results are also performed using
the Scanning Electron Microscope (SEM) and
the Atomic force microscope (AFM).
1. INTRODUCTI
ON
Up to date many efforts have been made to
understand the nature of tool wear, however, it
continues to have unsolved problems. Solutions
to these problems would bring a great
economical impact in machining industry.
However, a thorough understanding of the
micro-mechanisms involved in tool wear and a
meaningful method to measure it must precede
such solutions. So far, the traditional methods
used to measure tool wear have included
reflected light interference microscopy, scanning
electron microscopy, and stereo microscopy [1,
2]. However, due to the limitation on the depth of
field, the difficulty while obtaining and
interpreting images and the high cost involved,
these methods have proven to be burdensome
or behind the pinhole, therefore, few of these
rays make their way through the pinhole. As a
consequence, the image is formed mostly by
rays coming from the region of the sample
2. BACKGROU
ND
The confocal principle
The power of the CLSM resides in its ability to
get an image only from the light in the focal
plane. This means that all the out-of-focus light
is blocked from the final image allowing a
sharper image compared to the conventional
light microscope. This feature is achieved by
positioning a pinhole in the light path. Light that
is exclusively coming from the focal plane is
focused at a point right in the position of the
pinhole (Figure 1). The pinhole is positioned so
that it passes light from the focal plane to a
detector. Light rays originally coming from outof-focus regions have a focal point either in front
located in the focal plane. This process is the
main concept of optical section. An optical
section can be better understood as an
electronical slice of the sample coinciding with
Light Source
(LASER)
MIRROR
DICHROIC
(Beam splitter)
PHOTODETECTOR
(PHOTOMULTIPLIE
COLLECTING
LENS
P
M
T
OBJECTIVE
DETECTOR
PINHOLE
(Confocal
SCREEN
FOCAL PLANE or
OPTICAL
IN-FOCUS LIGHT RAYS
FOCUS
SPECIME
S T A G E
OUT-OF-FOCUS LIGHT
RAYS
3.1 Machinin
g tests
Dry turning tests were carried out in 8033
Clausing/Colchester lathe with the control for
infinitely variable speed. The experiments are
carried out at the constant feed of 0.3175 mm/
rev, depth of cut of 1.905 mm and constant
cutting speed of 250 m/min (820 sfpm). These
conditions are used based on the following
criteria: the range of optimal speeds provided by
the insert manufacturers, the need for obtaining
3 EXPERIMENTAL
PROCEDURE
2D VIEW
700m
HUMP
190 m
Trailing edge
Edge side limit
of the crater
Inland side limit
of the crater
Depression
Trailing edge
4. CONCLUSIONS
The usefulness of confocal microscopy to obtain
reliable surface profiles and topography was
confirmed. SEM and AFM microscopes aid was
relevant as validation tools for the CLSM
information. Also, the optical properties of steel
are found to have a distorting influence in the
results of the topography rendering. The
particular behavior of coated tools wear was
also verify [9, 10] and in particular the wear of
multi-layered coated has unexpected features
in the tool face and maximum crater depth
behavior. However, extended work and
analysis are currently being carried out to
interpret these
mechanisms.
results
in
terms
of
wear
Al2O3
exposed in
the crater
TiN hump
Steel
attached to
the TiN
coating
Al2
O3
100
0
800
600
400
200
0
200
400
600
800
M a c h i n i n g t i m e ( se c )
REFERENCES
Figure 5 Maximum depth locations
Maximum crater depth as a function
of machining time
Maximum crater depth (microns)
2.5
2
1.5
DEPTH
1
0.5
0
0
200
400
600
800