COMPARATIVE ANALYSIS OF

WEAR RATE OF COATED HSS

TOOL AND NON-COATED HSS
TOOL BY USING Cr-Zn-Ni
 ABSTRACT
• A research program was conducted to study tool wear on uncoated and
coated high speed steel (HSS) for fluted end mill cutters. These cutters
were used to machine aisi 4340 steel at axial and radial engagements. All
the machining was carried out using production conditions with the
process periodically interrupted to carefully measure the wear condition of
the cutting tool. Cutting conditions were carefully chosen so that a linear
wear model for the useful life of the cutting tool could be statistically
tested. One phase of testing used uncoated tools from different suppliers
and the nonstationary linear wear model provided a stochastic
representation to determine tool quality using reliability and economic
measures. Another phase used the coated tools and a stationary linear wear
model to relate force, power, specific cutting energy, and mechanistic
model parameters to service life measures.
• This paper also discussed about the tool wear and life factor after coating
compared with conventional cutting tool (high speed steel)
 INTRODUCTION
• High Speed Steel (HSS) tools have been extensively employed for
machining of different kind of materials through the past decades. HSS
tools show great toughness in comparison to other tool materials and
capable of withstanding against the cyclic or intermittent loading and
unloading. For this reason, they are primarily used for cutting operations at
which interrupted or intermittent cutting is likely to occur. These include
operations such as milling, drilling, broaching, and tapping. High speed
steels are also appropriate for producing tools of complex shape such as
helical milling, drilling, broaching, reaming, and tapping tools.
• However, when it comes to machining of hard-to-cut materials such as
chromium,zinc and nickel are coated by using physical vapour deposition
in (HSS) tools and predict the wear nature and hardness. chromium as a
coating for tool steels has been available widely since the last decade and is
enjoying increasing attention and application in tool industries.
 OBJECTIVES
• Study the wear progression on HSS cutting
tools .
• Study the change of surface finish throughout
the tool life of cutting tool
• Assess and analyze the results obtained for
HSS tool, and evaluate their performance
based on the effects of the coating materials
used.
PROCESS FLOW
 MATERIAL REQUIREMENTS
• Chromium
• Zinc
• Nickel
• Uncoated hss tool
 EXPERIMENTAL SETUP
• PHYSICAL VAPOUR DEPOSITION (PVD)
HSS TOOL IMAGE
CHROMIUM
 PROPERTIES OF CHROMIUM
S.NO NAMES VALUES UNITS

1 Density 7.19 g/cm^3

2 Melting point 1890 *c

3 Boiling point 2482 *c

ZINC POWDER
 ZINC PROPERTIES
DENSITY 7.14 g/cm³

COMPRESSIVE STRENGTH 55-67MPA

TENSILE STRENGTH 2.4-4.4GPA

NICKEL POWDER
 NICKEL PROPERTIES
DENSITY 7.81 g/cm³

YOUNG'S MODULUS 279 GPa

MELTING POINT 160 GPa

BOILING POINT 0.21

PVD (PHYSICAL VAPOUR DEPOSITION)
• The use of such coatings is aimed at improving
efficiency through improved performance and
longer component life. They may also allow
coated components to operate in
environments that the uncoated component
would not otherwise have been able to
perform. As mentioned previously, PVD
coatings are generally used to improve
hardness, wear resistance and oxidation
resistance
PVD IMAGE
 APPLICATION OF COATING

AUTOMOBILE COMPONENTS LIKE:

• CUTTING TOOLS
• MACHINE PARTS (BEARINGS, SHAFTS,
SPRINGS, ETC.)
 TESTS ARE INVOLVING
• WEAR TEST
• HARDNESS TEST
 RESULT
• To improve the wear strength
• To improve the hardness
• To improve the life of tool
 LITERATURE REVIEW

• A detailed literature survey of functionally graded coatings was carried out in

order to understand the properties of the coatings. Jingde Zhang et al (2003),
Khor et al (1999), Schulz et al (2003), Dong et al (1999, 2001), Demirkhan et
al (1999), Khor et al (1997, 2003), have extensively studied the plasma sprayed
FGC’s. This is to compare the properties of duplex coatings of mullite/nickel
chrome with the different types of plasma sprayed functionally graded coatings.
Similarly, functionally graded composites were studied by Kiebeck et al
(2003), Gang Jin (2005), Chakraborty (2008), Andertová (2007).
• Different coatings were developed by the author Daniel W. Parker (1992)
for different applications like turbo machinery, diesel engines for trucks,
power plants, marine applications and automobile uses.
• The basic information about vapour deposition from ionic liquids can be
found in a book from F. Endres [6]. Newer information about chromium
plating with ionic liquids is provided in [1, 2, 4, 7 to 10]
 REFERENCE
• S. Eugénio, C. Rangel, R. Vilar, A. M. Botelho do Rego: Electrodeposition of
black chromium spectrally selective coatings from a Cr(III)-ionic liquid
solution (2011) Thin solid Films 519 1845-1850
• Papasavva S., Kia S., Claya J., Gunther, R., Life cycle environmental
assessment of paint processes. Journal of Coatings Technology, 2002,
74/925:65-76.
• L.B.ABHANG and M. HAMEEDULLAH L.B.Abhang International Journal of
Engineering Science and Technology Vol. 2(4), 2010, 382-393
• H. Wang, A. Sharma, and A. Kvit Department of Materials Science and
Engineering, North Carolina State University, Raleigh, North Carolina 26
February 2001. Pp 27695-7916