Cutting Tool Materials

Seminar Presentation (6/18/20)

Presented by, Guided by,
ANAS P T (RET16ME027) Asst. Professor.
Mr. JEFFIN JOHNSON
Asst. Professor.
Mr. JOHN PAUL C D
Overview
• Introduction
• Ceramic Coated Cutting Tools
 Objectives
 Methodology
 Results and Discussion
• Recent Developments in Cutting Tool Materials
 Objectives
 Methodology
 Results and Discussion

Semester 7, Seminar Presentation

• Coated Cutting Tools
 Objectives
 Methodology
 Results and Discussion
• Conclusion
• References Department of Mechanical Engineering
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Introduction
• Many types of tool materials ranging from high carbon steel to ceramics and
diamond are used as cutting tool in today’s industry.
• Cutting tool materials constitute a special group of tool materials because they
must withstand extreme process condition specific for cutting.
• Cutting tool must withstand big mechanical loads and high temperature
simultaneously.
• As machining properties are highly related to cutting tool properties, recent
advanced development in cutting material and cutting tool coating are discussed.

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• Materials of coating, required thickness and substrate are discussed.

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Paper 1: Ceramic Coated Cutting Tool
( Cutting tools,1991, SAE 810320)

• Objectives

 To study on Al2O3 coating features on the cutting tool.

 To study the influence of Al2O3 on flank wear resistance during steel machining.
 To study the effect of Al2O3 coating thickness upon crater wear resistance.
 To study whether breakage resistance and thermal deformation resistance can be

Semester 7, Seminar Presentation

supplied by cemented carbide substrate.

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Paper 1: Ceramic Coated Cutting Tool
(Cutting tools,1991, SAE 810320)
• Methodology

 Ceramic cutting tools are preferred over cemented carbides for many applications
because they have better wear resistance to high temperature and high
compressive stress.
  Al2O3 has superior resistance to degrading chemical reactions.
 The Al2O3 coating is deposited by chemical vapour deposition(CVD) technique at

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uniform thickness(5 microns) and with high density.
 The flank wear resistance increases at a linear rate upto six microns thickness and
then levels off to a constant value (equal to that of a solid ceramic tool).

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Paper 1: Ceramic Coated Cutting Tool
(Cutting tools,1991 SAE 810320)

• Methodology (Cont.)

 The effect of Al2O3 coating thickness upon crater

wear resistance indicates that the coating need to
be very thick to be fully equivalent to that of solid
ceramic tool.

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 A thin adherent Al2O3 coating on the cemented
carbide provides ceramic level wear resistance
and carbide level breakage resistance. Courtesy:1981,cutting tools,810320

 The thermal deformation resistance for the

composite is provided by the ceramic coating.

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Paper 1: Ceramic Coated Cutting Tool
(Cutting tools,1991, SAE 810320)
• Results and Discussion
 Al2O3 coated cemented carbides(at about 6microns thickness) tools have flank
wear resistance equal to that of solid ceramic tools.
 Crater wear resistance is directly proportional to coating thickness.
 When the coating thickness is 6 to 10 microns the
crate wear is suppressed by flank wear even at
higher cutting speeds.

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 Ceramic coated tools has better performance in
many applications where the solid ceramics fails
by chipping or fracturing.

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Courtesy:1981,cutting tools,810320 7
Paper 2: Recent Developments in Cutting Tool Material
(Materials processing technology,1996, 56 16-23)

• Objectives
 To provide a brief overview of the recent development in cutting tool materials.
 The three groups considered are
(a) High speed steels,
(b) Cemented carbides

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(c) Ceramic/ superhard materials.

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Paper 2: Recent Developments in Cutting
Tool Material
(Materials processing technology,1996 56 16-23)

• Methodology
 Powder metal produced high speed
steels and titanium nitride coated steels
produced by physical vapour
deposition(PVD) is the most significant
recent development in the case of high
speed steels.

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 PVD titanium nitride coated high speed
steels a coating thickness of 3 to 4 μm
gives better performance than a thicker
coating in the range 6 to 8μm.

Courtesy materilas processing technology,56 16-23:

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Paper 2: Recent Developments in Cutting Tool
Material
(Materials processing technology,1996, 56 16-23)

• Methodology (Cont.)
 In cemented carbides the required bulk mechanical, thermal, and chemical
properties are achieved by alloying and engineering the surface by chemical
vapour deposition(CVD) and PVD.
 In binary WC-Co cemented carbides the toughness can be increased by
increasing cobalt content while wear resistance is increased by decreasing
cobalt content and decreasing carbide grain size.

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 The substitution of cubic carbide(TiC, NbC and TaC) for WC leads to
improvements in wear resistance and resistance to plastic deformation

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Paper 2: Recent Developments in Cutting
Tool Material
(Materials processing technology,1996, 56 16-23)

• Methodology (Cont.)
• In the case of ceramic materials fine grained alumina retains hardness and
compressive strength to higher temperatures than cemented carbides.
• The fracture toughness of alumina can be increased by addition of about 30%
by volume of the refractory carbide. This also has increased hardness and

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thermal conductivity
• Adding about 25% by volume of SiC whiskers has increased hardness,
fracture toughness, reduced thermal expansion coefficient and improved
thermal shock resistance.

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Paper 2: Recent Developments in Cutting
Tool Material
(Materials processing technology, 1996, 56 16-23)

• Results and Discussion

 For high speed steels the deposition of hard wear resistance ceramic layers, such as
titanium nitride layers by PVD techniques gives improvement in tool performance.
 For cemented carbides both CVD and PVD coating of tools with multilayers of

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different ceramics has led to improved performance.
 Alumina reinforced with silicon carbide whiskers has improved fracture toughness
and thermal shock resistance over alumina ceramics.

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Paper 3: Coated Cutting Tools
(Wear, 61, 283-293, elsevier)

• Objectives

 To assess the quality of Titanium Carbide coated inserts in high speed machining.
 To monitor and study the flank wear and crater wear of the TiC coated carbide
 Compare the flank wear and crater wear curve for TiC coated inserts from three
different suppliers.

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Paper 3: Coated Cutting Tools
(Wear, 61, 283-293, elsevier)

• Methodology

 TiC coated inserts were taken from three different suppliers and the cross sections
of each inserts were prepared to examine.
 A thin layer(5μm) coating of TiC on the cemented WC(Tungsten Carbide) tools
by chemical vapour deposition has improved resistance to crater wear.
 The flank curves for three different inserts are similar in nature with an initial

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wear of 25-100μm which increases slowly with time until after approximately 20
min machining the wear rate increased rapidly as the tools neared failure.

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Paper 3: Coated Cutting Tools
(Wear, 61, 283-293, elsevier)

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Courtesy:1980,wear,61,283-293 Courtesy:1980,wear,61,283-293

• Increase in flank wear after some minutes was indicated by excessive

vibration and sparking between tool and workpiece.
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Paper 3: Coated Cutting Tools
(Wear, 61, 283-293, elsevier)

• Results and Discussion

 The wear behavior of the flank face affect the high speed cutting performance of
coated tools.
 The initial wear on the flank is due to rubbing on the workpiece which is
superseded by a combined diffusion mechanism.

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 Breakdown in the rake face is by the adhesion wear mechanism between the
coating and the swarf which produces a thin layer of steel adhered to the coating.

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Conclusions
• It is found that the tool wear of coated tool is very low compared
with uncoated cutting tool.
• PVD coating is appropriate for High Speed Steels
• CVD coating is good for Ceramic Tools.
• All the coating perform better but the selection of the appropriate
coating material depend on the workpiece material and cutting

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condition.
• We need to improve the properties of cutting tools like hardness,
wear resistance, thermal deformation resistance with coating.

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References
• W. J. Reed and E. D. Whitney, "Ceramic Tools Chip Away at Productivity Problems", Machine &
Tool Blue Book, Aug. 1979, pp. 111-127
• M C Shaw. Metal Cutting Principles. Oxford University Press. 1984.
• E M Trent. Metal Cutting. Third Edition. Butterworth-Heinemann. Oxford 1991.
• E. M. Trent, Materials for metal cutting, Iron Steel Inst. (London) Publ., 126, 1970.
• B Mills. Unpublished work on TiN Coated High Speed Steels. [10]

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• N. P. Suh, "Coated Carbides -Past, Present, and Future", The Carbide Journal,
Jan.-Feb. 1977, pp. 3-9

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 Cutting tool failure process may be
unique for a particular combination of
tool and workpiece and may change
depending on lubrication and cutting
conditions.

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 Flank wear is an abrasion wear process and
a strong tool is required to offer resistance.
Crater wear is due to interdiffusion between
cobalt in the tool and iron in the steel and
decarburization of the tool.

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