Académique Documents
Professionnel Documents
Culture Documents
Fig. 3: The failure mode diagram for cBN-coated cutting tools in
machining of 34 CrNiMo 6 maps the forms of wear as functions
of cutting parameters
(a) crater wear (b) plastic deformation (c) fracture
(d) built-up edge (e) uniform wear
600 m 600 m 600 m
600 m 600 m
Fig. 4: Different forms of tool wear on cBN-coated cutting tools after
machining 34 CrNiMo 6 for 30 seconds: (a) crater; (b) plastic
deformation; (c) tool fracture; (d) build-up edge; (e) uniform
and continuously growing flank wear
process: cylindrical turning workpiece: GJS-500-7
cutting velo.:
c
= 1000 m/min feed: f = 0.1 mm
depth of cut:
p
= 0.5 mm
lubricant: dry
ISO code: CNMA 120408 hardness: 300 HB 30
v
a
6 -6 -6 95 80 0.8 mm
r r s 0 0
r
cutting time
c
t
w
i
d
t
h
o
f
f
l
a
n
k
w
e
a
r
l
a
n
d
V
B
m
450
150
0
0 300 75 150 s
CC PCBN cBN-K10
Fig. 5: Width of flank wear land in dependence on cutting time for
various cutting materials in machining spheroidal graphite cast
iron
Machining of Hardened Steels
Another important field of application of cBN tools is the turning
of hardened steel, which is a difficult machining task for new tool
coatings because of the high cutting forces. However, fig. 6 shows
that the cutting forces in turning D2 (hardness 62 HRC) with cBN-
coated tools and PVD TiAlN-coated tools are almost the same and
that they lie significantly below those of CVD TiCN-coatings. In
addition, the surface roughness of the machined workpiece with
cBN-coated tools is much better than the roughness achieved with
other tool coatings.
Conclusion and Outlook
The results of some of the first cutting experiments with cBN-
coated cemented carbide inserts were presented in this paper.
After an explanation of the approach used here to deposit adherent
cBN-coatings on cutting tool substrates at low temperatures, the
outstanding mechanical properties of cBN coatings were
summarized and compared to standard TiN-coatings. In particular,
the low surface roughness of the coating was compared with PVD
TiAlN-coatings and CVD TiCN coatings on the same cemented
carbide substrate.
Then, a failure mode diagram was introduced for the machining of
alloyed steel with cBN-coated inserts. It proved that cBN-coated
tools can generate all kinds of wear like common wear resistance
coatings: crater wear at high cutting velocities, plastic deformation
at high velocities and high feeds, tool fracture at high feeds, the
built-up edge effect at low cutting parameters, and uniform and
continuously growing flank wear in a so-called safe zone. This
result is important for the understanding of the wear behavior of
cBN coatings and for the enhancement of these tools.
Furthermore, the tool life of the machining of spheroid graphite
cast iron was presented in comparison with those of PCBN and
oxide ceramics. It could be proven that the tool life of cBN-coated
cutting tools is roughly 50 % of that of ceramic and 40 % of that
of expensive PCBN, whereby the tool geometry of the coated tool
may still be optimized.
Finally, the machining of hardened steel was analyzed and the
cutting forces and surface roughness were measured. In
comparison with other PVD and CVD tool coatings, the
workpiece roughness generated by cBN-coated tools is much
lower and the cutting forces, which are significantly lower than
those of CVD TiCN-coatings, are similar to those of PVD TiAlN-
coatings.
r
o
u
g
h
n
e
s
s
i
R
process: cylindrical turning workpiece: 1.2379
cutting velo.:
c
= 20 m/min feed: f = 0.1 mm
depth of cut:
p
= 0.5 mm
lubricant: dry
ISO code: CNMA 120408 hardness: 62 HRC
v
a
6 -6 -6 95 80 0.8 mm
r r s 0 0
r
c
u
t
t
i
n
g
f
o
r
c
e
s
i
F
m
12
4
0
PVD cBN-K10
N
600
200
0
PVD cBN-K10 PVD TiAlN-K10 CVD TiCN-K10
PVD TiAlN-K10 CVD TiCN-K10
F
c
F
F
f
p
R
max
R
R
z
a
Fig. 6: Cutting forces and workpiece roughness in dependence on
cutting materials in machining hardened steel
Summing up, cBN tool coatings are eligible for the machining of
various workpiece materials even at high cutting velocities. The
machining of hardened steels is also possible. The achievable
workpiece roughness is better than that of other PVD and CVD
tool coatings. However, the applicable cutting velocities and
achievable tool lives of cBN-coatings are still lower than those of
some other tools. The next steps to counter these problems are the
increase of coating thickness and the implementation of a
rotational mechanism during coating.
References
1 Wentorf Jr., R. H.: Chem. Phys., 26 (1957) 956
2 Kester, D. J.; Messier, R.; Vac, J.: Sci. Technol. A 12 (6) (1994) 3074
3 Tanabe, N. et al.: Diamond Relat. Mater. 1 (1992) 151
4 Schtze, A.; Bewilogua, K.; Lthje, H.; Kouptsidis, S.; Jger, S.: Surf.
Coat. Technol. 74-75 (1995) 717
5 Ikeda, T.; Kawate, Y.; Hirai, Y.; Vac., J.: Sci. Technol. A8(4) (1990)
3168
6 Murakawa, M.; Watanabe, S.; Miyake, S.: Diamond Films Technol. 1
(1991) 55
7 Mirkarimi, P. B.; McCarty, K. F.; Medlin, D. L.: Materials Science
and Engineering, R21 (1997) 47
8 Weber, A.; Bringmann, U.; Nikulski, R.; Klages, C.-P.: Diamond
Relat. Mat. 2 (1993) 201
9 Litvinov, D.; Clarke, R.: Appl. Phys. Lett. 74 (1999) 955
10 Matsumoto, S.; Zhang, W.: Jpn. J. Appl. Phys. Vol. 39 (2000) 442
11 Donner, W.; Dosch, H.; Ullrich, S.; Erhardt, H.; Abernathy, D.: Appl.
Phys. Lett. 73 (1998) 777
12 Boyen, H.-G.; Widmayer, P.; Schwertberger, D.; Deyneka, N.;
Ziemann, P.: Appl. Phys. Lett. 76 (2000) 709
13 Yamamoto, K.; Keunecke, M., Bewilogua, K.: New Diamond and
frontier carbon technology, Vol. 10, No. 4, 2000
14 Yamamoto, K.; Keunecke, M., Bewilogua, K.: Thin Solid Films, 398-
399 (2001) 142-149
15 Yamamoto, K.; Keunecke, M., Bewilogua, K.; Czigany, Z.; Hultmann,
L.: Surface and Coating Technology, 142-144 (2001) 881- 888