Machining Hard Materials Using Coated Cutting Tools

This paper discusses improvements associated with the life of cutting tools used to machine M42 tool steel,Titanium alloy (Ti-64)and modified AISI P20 tool steel.Titanium is one of the important metals is used in various fields of engineering and medical sciences.In order to assess the impact of different tool coatings on the machining process, initial experiments simulate existing machining operations; this provides a standard for tool life and surface finish. The findings in the paper show that TiAlCrYN coated WC-Co cutting tools perform better than uncoated cutting tools to machine M42 tool steel. The implications of the paper tend to indicate that machining M42 tool steels without lubricant can be optimized using coated cutting tools. Polycrystalline diamond (PCD) can be successfully used to machining of titanium alloy (Ti-64) and modified AISI P20 tool steel using TiN coated inserts. The limitations of the paper include machining at one specific cutting speed and the employment of a short-time tool wear method. The practical implications of the paper show that dry machining of hardened tool steels can be achieved under certain circumstances.One of the main pre-requisites for successful industrial production is the use of quality coated cutting tools with defined mechanical and technological properties. Therefore, for the development and introduction of new coated cutting tool (new combination of cutting material and hard coatings), it is necessary to carry out a number of studies with the purpose to optimize the coatings composition and processing procedures, and also to test new tools in working conditions. The requirements from industry areto produce faster, better, safety and more ecologically, force us to develop new effective tools and innovative technologies. This provides a technological challenge to the scientists and engineers and increases the importance of knowing several scientific disciplines. In general, a finish machining of a titanium component will be necessary, because of the requirement of exact dimensional accuracy, surface quality and material homogeneity. Machining of titanium alloy poses considerable problem due to its poor machinability. The poor machinability of titanium has led many large companies (for example Rolls-Royce and General Electric) to invest largeamount of money in developing techniques to minimize machining costs. Similarly, tool makers are looking for new tool materials which can extend tool life in the presence of such a challenge.