BTP results

1. Contents
1.ABSTRACT.................................................................................................................................................2
4.INTRODUCTION........................................................................................................................................2
5.LITERATURE REVIEW.................................................................................................................................2
6.EXPERIMENTAL DETAILS...........................................................................................................................2
7.RESULTS....................................................................................................................................................3
COATING ROUGHNESS.............................................................................................................................3
SCRATCH TEST..........................................................................................................................................4
Critical load..........................................................................................................................................6
MICROHARDNESS....................................................................................................................................6
.....................................................................................................................................................................6
PIN ON DISC ............................................................................................................................................7
.....................................................................................................................................................................8
μ versus conditions..............................................................................................................................9
Wear coefficient versus conditions due to carbide ball......................................................................9
Wear coefficient versus conditions due to steel ball........................................................................10
CUTTING FORCE.....................................................................................................................................11
Px Versus Vc.......................................................................................................................................11
Pz Versus Vc.......................................................................................................................................14
...............................................................................................................................................................14
ζVersus Vc..........................................................................................................................................17
F/N Versus Vc....................................................................................................................................20
TOOL WEAR TEST...................................................................................................................................23
30 seconds........................................................................................................................................23
1 min......................................................................................................................................................23
Figure 36 1 min..................................................................................................................................24
1.5 min..................................................................................................................................................24
2 min..................................................................................................................................................26
4 min..................................................................................................................................................27
CUTTING VELOCITY = 151 m/min...........................................................................................................29

2. CUTTING VELOCITY = 196m/min ..................................................................................30
.................................................................................................................30
4..
1. ABSTRACT
2. The use of coated tools is firmly established in today's metal cutting industry. Layers of
wear-resistant materials only microns thick are deposited onto conventional tool
substrates to bring about significant improvements in tool performance and cutting
economies through lower tool wear, reduced cutting forces and better surface finish of the
workpiece Such coatings have also extended the range of workpiece materials and cutting
conditions under which conventional tools are able to machine.
3. Although coated tools have been in commercial use for three decades, much is still
unknown about the behaviour of these tools throughout their recommended range of
machining conditions. While it is commonly acknowledged that coatings increase wear
resistance, reports of the extent of the improvement differ widely
4. INTRODUCTION
5. LITERATURE REVIEW
6. EXPERIMENTAL DETAILS

3. 7. RESULTS
COATING ROUGHNESS
Figure 1 Coating Roughness

4. SCRATCH TEST
Figure 2 Old magnetron -45V
Figure 3 Old Magnetron -60V

5. Figure 4 New Magnetron -45V
Figure 5 New Magnetron -60V

6. Critical load
Figure 6 Critical Load
MICROHARDNESS
Figure 7 Microhardness

7. PIN ON DISC
Ti Current
N2 flow
Ar flow
Bias
Temperature
Pressure
Figure 8 Old Magnetron -45V
Ti Current
N2 flow
Ar flow
Bias
Temperature
Pressure
Figure 9 Old Magnetron -60V

8. Ti Current
N2 flow
Ar flow
Bias
Temperature
Pressure
Figure 10 New Magnetron -45V
Ti Current
N2 flow
Ar flow
Bias
Temperature
Pressure
Figure 11 New Magnetron -60V

9. μ versus conditions
Figure 12 sliding coefficient of friction versus conditions
Wear coefficient versus conditions due to carbide ball
Figure 13 Wear coefficient versus conditions due to carbide ball

10. Wear coefficient versus conditions due to steel ball
Figure 14 Wear coefficient versus conditions due to steel ball

11. CUTTING FORCE
Px Versus Vc
Figure 15 Old Magnetron -45V
Figure 16 Old Magnetron -60V

12. Figure 17 New Magnetron -45V
Figure 18 New Magnetron -60V

13. Figure 19 Uncoated

14. Pz Versus Vc
Figure 20 Old Magnetron -45 V
Figure 21 Old Magnetron -60 V

15. Figure 22 New Magnetron -45 V
Figure 23 New Magnetron -60 V

16. Figure 24 Uncoated

17. ζVersus Vc
Figure 25 Old Magnetron -45V
Figure 26 Old Magnetron -60 V

18. Figure 27 New Magnetron -45V
Figure 28 New Magnetron -45V

19. Figure 29 Uncoated

20. F/N Versus Vc
Figure 30 Old Magnetron -45V
Figure 31 Old Magnetron -60V

21. Figure 32 New Magnetron -45V
Figure 33 New Magnetron -60V

22. Figure 34 Uncoated

23. TOOL WEAR TEST
CRATER FLANK
OLD -45 CRATER FLANK
OLD -45
OLD -60
Figure 35 30 seconds
OLD -60
NEW-45
NEW-45
NEW-60
NEW-60
UNCOATED
UNCOATED
30 seconds
Figure 35 30 seconds
1 min

24. Figure 36 1 min
1.5 min
Figure 37 1.5 min

25. CRATER FLANK
OLD -45
OLD -60
NEW-45
NEW-60

26. 2 min
CRATER FLANK
OLD -45
OLD -60
NEW-45
NEW-60
Figure 38 2 min

27. 4 min
CRATER FLANK
OLD -45
OLD -60
NEW-45
NEW-60
Figure 39 4 min

28. Figure 40 Tool wear

29. CUTTING VELOCITY = 151 m/min
OLD -45 0.08 0.12 0.16 0.20
OLD -45
OLD -60
OLD -60
NEW-45
NEW-45
NEW-60
NEW-60 UNCOATED
UNCOATED 0.08 0.12 0.16 0.20

30. CUTTING VELOCITY = 196m/min